Industrial Machinery Digest - January, 2020

» Workforce Values and the Strategy of Diversity » “Cold Turkey” Approach to Robotic Handling » Laser Cutting vs. Water Jet Cutting: Knowing the Difference and When to Use Which » Improved Machining Solutions – Today

Manufacturing Showcase: EMAG IndustrialMachineryDigest.com

January 2020

SAVE MORE WITH RADWELL VERIFIED SUBS High quality brand new functional product replacements that can be substituted for the original manufacturer’s item at significant savings. All with a three-year warranty!

To learn more visit - https://info.radwell.com/verified-subs Disclaimer: This publication is not sanctioned or approved by any manufacturer or tradename listed. Radwell International, Inc is not an authorized distributor or representative for the listed manufacturers. Layout of data used in this publication is Copyright © 2017 All rights reserved.

Customized Safety Lifting Devices For Any Application

Safely Lifts Up To 500 lbs!

Ergonomic Portable Lightweight Meets OSHA & ASME Requirements

800-4-SKYHOOK 800-475-9466 • 208-365-5770

www.skyhookmfr.com

The Sky Hook is your personal safety lifting solution, preventing lifting injuries while saving you both time and money!

®

CUT LIKE A BOSS

With SCOTCHMAN Manual To Fully Automatic Sawing Solutions

• FERROUS & NON-FERROUS MODELS • BEST WARRANTY • FINANCING AVAILABLE

Schedule Your FREE On-Site Demo Today

www.scotchman.com

PROUD AMERICAN MANUFACTURER EST. 1967

Table of Contents

COLUMNS

10

BUSINESS 4.0 The Growing Value of Industry 4.0 Industrial Internet of Things (IIoT) Market Worth $156.6 Billion by 2024 - Exclusive Report by MarketsandMarkets™

20

FEATURES

20

14

MANUFACTURING SHOWCASE

EMAG

14 16

By: Russ Willcutt

22

26

DEPARTMENTS

NEW TECH “Cold Turkey” Approach to Robotic Handling

By: Michael Castor, Product Manager, Material Handling at Yaskawa America Inc. – Motoman Robotics Division

30 PROCESS

Laser Cutting vs. Water Jet Cutting: Knowing the Difference and When to Use Which

34

SAFETY & MAINTENANCE Taking an Incremental, Multi-Stage Approach When Upgrading Aging DCS Systems

WORKFORCE DEVELOPMENT Workforce Values and the Strategy of Diversity By: Andrea Belk Olson, MSC and CEO of Pragmadik

TALKING SHOP Steven Holmes CNC Education Manager, Siemens

INDUSTRY INSIGHTS Improved Machining Solutions – Today Servicemold + Aerospace Inc. Tracks Growth From Zimmermann Milling Machines

6 8 38 40

EDITORIAL DIRECTIONS INDUSTRY NEWS ON EXHIBIT PACIFIC DESIGN & MANUFACTURING

ON EXHIBIT HOUSTEX

44 PRODUCT SHOWCASE 46 SURPLUS BUYING AND SELLING 49 CLASSIFIEDS 50 ADVERTISER INDEX

ON THE COVER

22 |

4 IMD JANUARY 2020

Radwell International stocks and sells New and Surplus Industrial Automation, MRO, Pneumatic, Motion, Electronic, Hydraulic, HVAC and Electrical Control Equipment for plant floor and facilities maintenance machinery.

Plate Rolls

20 Ga to 6” Capacities, CNC Controls , Vertical Systems, Translating Geometry & More!

NEW! Stradivari CNC 3-D CAD graphic controls, “Field-Bus” and “Facile” Systems Technology

4 Roll 3 Roll 2 Roll

Over 100+ Units in Stock Backed by Superior Warranties & Service

Co Innovation, Q ua m li

ck

ed

ty

lume Needs h Vo Hig ecades D O f to By Ex

ess o Succ - Job Sh t d ops rmance tte mi & Perfo Ba

p

ce ien er

Visit Us Online or Call: (251) 937-0947

www.carellcorp.com • www.eaglebendingmachines.com sales@carellcorp.com • sales@eaglebendingmachines.com

Editorial Directions SERVING AMERICAN MANUFACTURERS FOR OVER

One of the things I enjoy most about interviewing OEMs is when I encounter a company that is truly dedicated to building deep, lasting relationships with its customers. Sure, everybody says that’s their goal, but there are ways you can tell whether they really mean it or not. One has to do with their reputation within their industry, of course, as well as how many years they’ve been in business and how well they’ve prospered. Another is the median time range they’ve managed to retain a significant percentage of their key accounts. But, to me, there’s one more marker that best describes a healthy, ongoing relationship between vendor and end user, and that’s when the OEM can actually point to lessons it has learned from its customers, and is quick to express gratitude for the opportunity.

For instance, when we refer to the “human machine interface,” or HMI, we’re generally talking about the control panel, but in a larger sense that also has to do with the anatomical movements of the physical body as it relates to the mechanical motions of a machine. And sometimes that can’t be predicted in advance of a machine tool’s installation with a particular environment, or operation, or production line, or application. I can think of instances where line-of-sight considerations involving alarm lights or material infeeds, when reported to the OEM, resulted in design changes to the machine tool platform in its entirety, improving performance overall. Same thing with part-cleaning techniques within the enclosure, and streamlined methods for chip evacuation, disposal, and fluid recovery. I recall one OEM who helped a customer land an account in a market neither had previously serviced, mingling engineers from all three companies with everyone gaining from the experience — especially the OEM, who was able to use its newfound knowledge of both processes and new materials to broaden its product line.

The takeaway for me is that, at a time when everyone feels rushed and perhaps tempted to cut corners a little, it’s a good idea to stop and remind ourselves why keeping our word, paying attention to the people who allow us to make our living, and remembering the value of a good reputation still matters.

And you'll sometimes receive an unexpected ROI!

33 YEARS

William C. Strickland III, Publisher william.strickland@indmacdig.com 800-366-0676 ext. 103 | Fax: 866-826-5918

Russ Willcutt, Editorial Director russ@indmacdig.com

Nick Boliek, Editor nick@indmacdig.com 800-366-0676 ext. 104 | Fax: 866-826-5918

Shane Bell, Creative Director sbell@indmacdig.com

SALES

Lisa Hanschu, Sr. Account Executive lisa@indmacdig.com 785-965-9159 | Fax: 785-965-7199

David Marlow, National Sales Director David@indmacdig.com 800-366-0676 ext 200

William C. Strickland III, National Sales 205-903-9178 | fax 866-826-5918

Adrienne Gallender, Media Adviser agallender@indmacdig.com 888-407-7737

Susan Strickland, Accounting susan@indmacdig.com 205-542-1098 | Fax: 866-826-5918

Sarah Mayo, Interactive Specialist sarah.mayo@indmacdig.com 800-366-0676 | Fax: 866-826-5918

CIRCULATION & SUBSCRIPTIONS IMD, 3590-B Hwy 31 South, Suite 233, Pelham, AL 35124 circulation@indmacdig.com | Fax: 866-826-5918

REPRINTS To purchase article reprints please call 800-366-0676 ext. 103 or email wstrickland@indmacdig.com

Russ Willcutt Editorial Director, Industrial Machinery Digest

source

360 media llc

A PUBLICATION OF:

Source 360 Media LLC 3590-B Hwy 31 South PMB #233 Pelham, AL 35124

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. Oneyear subscription to nonqualified individuals in the United States: $9600.

Single copies available (prepaid only) $2000 each.

Alabama Automotive Manufacturers Association

|

6 IMD JANUARY 2020

M

ADE IN TH

E

USA

100%

The Best Tool Cabinet You Will Ever Buy GUARANTEED IN

E V E R Y W AY

MADE BY AMERICAN CRAFTSMEN IN THE USA

WWW.STORLOC.COM • 1-800-STORLOC 1-800-786-7562 sales@storloc.com

Industry News U.S. Manufacturing Technology Orders Increase in October of 2019 U.S. Manufacturing Technology Orders totaled $376 million in October 2019 according to the latest U.S. Manufacturing Technology Orders (USMTO) Report published by AMT – The Association For Manufacturing Technology. October orders increased 2 percent over September 2019. The industrial machinery manufacturing sector experienced robust growth in October 2019. Orders from machine shops grew at a modest pace but have not returned to their latersummer levels. The automotive sector increased orders by about 40 percent in October, while the aerospace sector decreased orders by slightly over ten percent.

FABTECH 2019 Sees Record Attendance in Chicago FABTECH 2019, North America’s largest metal forming, fabricating, welding and finishing event, hosted an enthusiastic crowd at Chicago’s McCormick Place November 11-14. Despite the unexpected winter weather, the 2019 event closed with record attendance, marking a 7 percent increase over the previous FABTECH Chicago. A total of 48,278 attendees from 95 countries participated in four full days of product evaluation, education and collaborative discussions on key industry issues. Three massive exhibit halls full of more than 500 new products and 1,700 exhibitors highlighted the emerging trends and technologies influencing the future of manufacturing. For the first time, FABTECH expanded into the Lakeside Center with early access to give attendees a jump start on the first day of the show. During the show, the five FABTECH event partners announced that beginning in 2021, FABTECH Chicago-previously held in November-will shift its dates to September. The event, hosted in odd years at Chicago’s McCormick Place, will make its next visit to the Windy City on September 13-16, 2021 and remain in September in future odd years.

Exact Metrology Employee Shares His Experience Jason Kleinhenz is one of many Exact Metrology employees at the company’s Cincinnati office, located at 11575 Goldcoast Drive. While he does not have an official job title at the company, Kleinhenz describes himself both as an engineer and as a trainer. His job duties include managing and performing training, as well as marketing and

creating content for Exact Metrology. According to Kleinhenz, “The best part of working in metrology is that one day you might be working on a rocket and the next day on a beautiful piece of art (and everything in between).” Regarding his most memorable experience at Exact Metrology, he mentioned his trip to Peru this past summer.

During two weeks, he helped scan Peruvian artifacts for preservation and deliver school supplies to a rural community. “My mission in life is to relay joy, love and enrichment. Peru was a great experience because I was able to check the box of each of those, and the relationships and communities formed are invaluable.”

Weiler Abrasives Group Raises $100,000 to Support Pocono Mountains United Way The generous employees of Weiler Abrasives Group, the Crescobased global abrasives manufacturer, raised more than $40,000 in their annual campaign benefiting Pocono Mountains United Way. The company matched that effort with a $60,000 corporate contribution, bringing Weiler’s total donation to $100,000. The money raised will support Pocono Mountains United Way’s Monroe County programming initiatives that address poverty alleviation, healthy food access, and critical housing needs for local families. To help promote the United Way campaign was 75 days long, themed “75 Days of Giving,” and culminated at Weiler’s Family Day Fall Festival, a celebration of the company’s 75th anniversary.

Mazak DISCOVER 2019 Draws Thousands of Attendees DISCOVER 2019 featured over 30 live machine tool demonstrations, and Mazak unveiled for the first time in North America several productivity-enhancing technologies such as its new MAZATROL SmoothAi control as well as a new mixed reality training and service support system. The company also showcased some of its investments in its Florence, Kentucky, manufacturing campus, including a sneak preview of the latest improvements to its Mazak iSMART Factory™ and a new Spindle Rebuild Facility in the campus’ South Building. As part of DISCOVER 2019, Mazak opened the doors of its Mazak iSMART Factory for tours, during which attendees experienced the company’s latest investments in its own manufacturing operations, including a new completely automated manufacturing cell currently being installed and the initial stages of the entirely new Spindle Rebuild facility. This new state-of-the-art facility will provide efficient and high-quality OEM-factory-certified spindle rebuild services and will further improve Mazak’s ability to quickly deliver spindles and reduce customer downtime.

Jason Kleinhenz, Exact Metrology

Chief Financial Officer joins Magline, Inc.

CONNECT WITH US ONLINE Visit our website or connect with IMD on social media! www.IndustrialMachineryDigest.com

|

8 IMD JANUARY 2020

Magline, Inc., manufacturer of Magliner® aluminum material handling equipment, announces the addition of John Baird as Chief Financial Officer. Baird is responsible for the organization’s Finance, Human Resources and Information Technologies business units. Baird joins Magline following his most recent position as CFO/VP of Operations at Paragon Technologies, Inc. based near Detroit, Michigan. His responsibilities with Paragon Technologies included planning, directing and coordinating all financial, support and production operations required to obtain the company’s growth objectives.

IMD – The Industry’s Most Extensive Industrial Publication

“I am looking forward to the opportunity to work with the Magline team and having a positive impact on the organization,” stated Baird, “My experience aligns perfectly with the needs Magline has today and the leadership skills they require to continue to execute their aggressive business strategy.”

Radian Laser Systems Announces New Partnership with PAT Technology Systems, Inc. Radian Laser Systems produces high-quality industrial laser systems utilizing galvo-based CO2 and fiber laser sources. With any marking and engraving system, a high-quality fume extractor is necessary to ensure the safety of the working environment from fumes. smoke and unpleasant odor. Radian recently decided to test the Filtrabox fume extractor from PAT Technology Systems. Inc. with our new laser marking module at Fabtech 2019. Based on our exceptional results, Radian Laser Systems has decided to partner with PAT Technology Systems, Inc. to offer their industry-leading fume extractors for use with our laser marking systems.

"We chose to partner with Filtrabox in particular due to the quality of the machine, ease of maintenance and a trusted relationship," says Radian Laser Systems CED, Tom Tamburrini. "Radian Laser and PAT Technology have similar values, we both believe in deploying innovative solutions to meet the demands of our customers for today and for the future," says PAT Technologies President. Wayne Baird.

AHB Tooling & Machinery Acquires Tool-Craft Supply AHB Tooling & Machinery has announced the acquisition of Tool-Craft Supply. The acquisition is effective as of December 2, 2019. Tool-Craft Supply had previously been a part of Tool-Craft Industries of Sterling Heights, Michigan. Tool-Craft Industries will continue to operate as an independent entity under the leadership of Chet Wilson, its president. With the acquisition of Tool-Craft Supply, AHB customers now have access to the quality custom cutting tools for which Tool-Craft has become known. Additionally, Tool-Craft offers full special cutting tools with limited lead times, allowing you to increase productivity and save money.

“We are excited to have found a leader to provide focus on our high-end metrology businesses,” said Mr. Douglas A. Starrett, President, and CEO of Starrett. “David has deep experience with products and channels similar to Starrett, a global perspective and a growth mindset that will help these businesses grow faster and more profitably.”

Sumitomo Electric Carbide Joins OMIC R&D as 30th Member Sumitomo Electric Carbide, Inc. (SCI) is known for its development and manufacture of cemented carbide, CBN and sintered diamond cutting tools, wear-resistant tools and their materials, laser optics for laser processing machines and diamond products for electronics parts. Craig Campbell, executive director of OMIC R&D said, “Sumitomo shares OMIC R&D’s desire for active and engaged members. They are known to have a technology first mentality and they bring unique solutions to the discussion that will help us solve industry’s machining challenges. Sumitomo possesses an energy and excitement that fits very well with our hands-on approach to solving problems.” SCI’s mission includes providing superior products, technologies, and services to satisfy various customers on the global market; and realizing sustainable growth through innovative and advanced technology development. They currently have about 4,000 employees worldwide.

Virtual Symposium Stresses Value of Safety Management Systems The American Society of Safety Professionals (ASSP) is holding a one-day virtual symposium on Wednesday, January 15, that will focus on occupational health and safety management systems and how they can reduce injuries, illnesses and fatalities in any organization. The symposium will include four webinars and provide registrants with two standards for free. Webinar presenters will review differences between ISO 45001 and ANSI/ASSP Z10.02019 to help participants determine which safety management system is right for their organization. “Safety management systems serve as a foundation that enables organizations to integrate critical processes to improve safety,” said ASSP President Diana Stegall, CSP, CFPS, ARM, SMS, CPCU. “Incidents that harm workers occur far too often in every industry. Most occupational injuries and illnesses are preventable.”

Starrett Appoints David Allen As Metrology Systems Vice President The L.S. Starrett Company, a leading global manufacturer of precision measuring tools and gages, metrology systems and more, has announced the appointment of Mr. David Allen as Vice President, Starrett Metrology Systems, effective November 18, 2019. In this newly-created role, Mr. Allen will be responsible for the strategy, growth, and profitability of the advanced metrology systems including Starrett Bytewise, Starrett Tru-Stone Technologies, Starrett-Kinemetric Systems, metrology software development, force measurement systems, and Starrett Special Gage Department.

Precision Rotary Atomizer Technology For Effective Industrial Spraying Precise droplet size- adjustable electronically Very low energy use Long life, low maintenance Brushless motor technology

www.micron.co.uk

Micron Sprayers Ltd, Bromyard, Herefordshire, England UK Tel: +44 1885 482397 email: sales@micron.co.uk

INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 9

Business 4.0

The Growing Value of Industry 4.0

Industrial Internet of Things (IIoT) Market Worth $156.6 Billion by 2024 - Exclusive Report by MarketsandMarkets™

A

ccording to latest market research report (IoT, Artificial Intelligence, Industrial Metrology, Industrial Robotics, AR & VR, Blockchain, 3D Printing, Digital Twin, and 5G – Offering, Application, and End Users) and Geography- Global Forecast to 2024", published by MarketsandMarkets™, the Industry 4.0 Market is estimated to be valued $71.7 billion in 2019 and is expected to reach $156.6 billion by 2024, at a Compound Annual Growth Rate (CAGR) of 16.9 percent from 2019 to 2024.

Increasing adoption of the industrial internet worldwide in manufacturing units and growing focus on enhanced efficiency

|

10 IMD JANUARY 2020

of machinery and systems and reduced production costs play a significant role in the growth of the market worldwide. Also, the growing demand for industrial robotics is expected to fuel the growth of the Industry 4.0 market.

5G Market Is Expected To Commercialize In Late 2019 And Is Expected To Grow At Highest CAGR During Forecasted Period.

The speed and reliability of 5G are expected to have a massive impact on M2M and IoT. Key reasons for the increased adoption

of new M2M technologies are better connectivity for smooth communication and low power requirement. To achieve effective machine-to-machine communication, the existing capacity of mobile networks must be able to handle billions of nodes that are expected to ascend in the next couple of years. Currently, the network capacity is inefficient to handle M2M and human-based communications, as well as their different communication patterns such as latency time.

Iot Is Expected To Hold Largest Market Share Of Industry 4.0 Market During Forecasted Period Internet of Things (IoT) in the industrial sector has given rise to

|

12 IMD JANUARY 2020

the Industrial Internet of Things (IIoT), also known as Industrial Internet or Industry 4.0. IoT in the industrial sector brings together advancements of two transformative revolutions, namely, the countless machines, facilities, fleets, and networks that emerged from the industrial revolution and the more recent powerful advancements in computing, information, and communication systems brought about by the internet revolution.

APAC is expected to hold largest market share of Industry 4.0 market during forecasted period An increase in the adoption of robotics in countries such as China, Japan, and South Korea is among the major factors leading to the

growth of the Industry 4.0 market in APAC. Also, low production cost in APAC countries enables manufacturers to set up manufacturing facilities in this region. APAC is projected to grow at the fastest rate, considering continuous technological advancements and financial support from the governments in the region, as well as extensive industrial base, with Japan and China being the major contributors.

China has been working on an innovative industrial practice by implementing automation technologies in manufacturing companies.

The major players in the Industry 4.0 market are ABB (Switzerland), Mitsubishi (Japan), Yaskawa (Japan), KUKA (Germany), FANUC (Japan), General Electric (US), IBM (US), Cisco (US), Microsoft (US), Stratasys (US), Google (US), Intel (US), HP (US), Siemens (Germany), Ansys (US), AIBrain (US), SAP (US), Amazon Web Services (US), and General Vision (US).

collaboration with the clients to identify new opportunities, identify

ABOUT MARKETSANDMARKETS

Contact:

MarketsandMarkets™ provides quantified B2B research on 30,000

MARKETSANDMARKETS™ INC.

most important customers, write "Attack, avoid and defend" strategies, identify sources of incremental revenues for both the company and its competitors. MarketsandMarkets™ is now coming up with 1,500 MicroQuadrants (Positioning top players across leaders, emerging companies, innovators, strategic players) annually in high growth emerging segments. MarketsandMarkets™ is determined to benefit more than 10,000 companies this year for their revenue planning and help them take their innovations/disruptions early to the market by providing them research ahead of the curve.

MarketsandMarkets™'s flagship competitive intelligence and market research platform, "Knowledge Store" connects over 200,000 markets and entire value chains for deeper understanding of the unmet insights along with market sizing and forecasts of niche markets.

high growth niche opportunities/threats which will impact 70 percent to 80 percent of worldwide companies revenues. Currently servicing

Mr. Shelly Singh

7500 customers worldwide including 80 percent of global Fortune

630 Dundee Road

1000 companies as clients. Almost 75,000 top officers across eight

Suite 430

industries worldwide approach MarketsandMarkets™ for their painpoints

Northbrook, IL 60062

around revenues decisions. Their 850 fulltime analyst and SMEs at

USA: +1-888-600-6441

MarketsandMarkets™ are tracking global high growth markets following

Email: sales@marketsandmarkets.com

the "Growth Engagement Model – GEM". The GEM aims at proactive

Web Site: www.marketsandmarkets.com

Multiple Machining

Tailor-made and standard multi-spindle heads for drilling and tapping in tight spaces and in the shortest amount of cycle time.

SUHNER INDUSTRIAL PRODUCTS CORP. 43 Anderson Rd SW, Rome, GA 30161 706.235.8046 machining.usa@suhner.com

Suhner AD5495a Mutiple 2017 IMD

Innovative products, full service for machine manufacturers • Direct access to SOMEX’s expertise • Parts retrieval from SOMEX stocks • Low life-cycle cost SUHNER INDUSTRIAL PRODUCTS CORP. 43 Anderson Rd SW, Rome, GA 30161 706.235.8046 machining.usa@suhner.com

INDUSTRIAL MACHINERY DIGEST.COM

Suhner AD5495e Innovative 2017 IMD

|

IMD 13

Talking Shop We’ve reached a tipping point where the skills gap is now a mainstream news topic that everyone is aware of, and industry and academia have joined forces to develop effective solutions.

FEATURING:

TALKING SHOP WITH: Steven Holmes — CNC Education Manager, Siemens What was the impetus behind the launch of the LEAP initiative in 2017?

The Lifelong Educational Advantage Program, or LEAP, was launched as an offshoot of Siemens Cooperation with Education, which was already in place at the time. SCE was active at our locations throughout Europe and the USA, so we were able to use that experience as a model for a similar initiative here in the States. Siemens has some 350,000 employees worldwide, and approximately 65,000 in the U.S., so we had thousands of people with a lot of experience to draw from in offering training opportunities to students in high schools and secondary institutions such as technical programs, community colleges and universities.

How did you go about approaching high schools and technical programs about enrolling in LEAP? How do they get started, and what costs do they incur?

We already had longtime relationships with about 500 U.S. academic institutions at the time, so we were able to use that as a starting point as we began reaching out to other potential enrollees. The schools that apply and are approved receive a 90 percent discount on the Sinutrain training system they receive, which turns any PC screen into an almost exact representation of the Sinumerik 828D and 840D sl controls on the machine. As for the training, we train and certify the instructors, who then train the students who are working toward their own certifications. The schools pay no extra cost beyond their initial software investment.

Be smarter and more flexible — see how.

With Siemens, control my future.“

achine shop owner, I want to be smarter and more flexible manufacturing; I want to be more competitive. So when ted in my CNC machine, I insisted on the control system IMD 14 |the elivers greatest returns.

JANUARY 2020

When the program mentions “hands-on” training, does this describe onscreen exercises or actual exposure to a machine tool?

The training modules vary, depending on what the student is drawn toward. If it’s turning, there are two levels, with the first being conversational — mostly onscreen work — and the second focusing on writing G-Code. If it’s milling they choose, there is a third level for 5-axis machining. They have a wealth of resources on our Siemens CNC4you web site, including webinars and live machining demos. As for the hands-on portion, once they’re ready the students are required to develop their part programs which are verified with 3D graphics, paying special attention to any potential collision scenarios, and then to have their instructor sign off on the results before they load it into an actual machine at their facility.

They must prove to the instructor that they can run the part they’ve designed before they’re eligible for certification. When they have that in hand, they are very desirable as a candidate once they enter the job market.

In the two years that this initiative has been in place, can you speak to growth in terms of enrollees and/or industry partner OEMs? In 2017, starting with six or seven schools that had been approved for entry into the program, since then we’ve seen that number double every year, with more than 50 academic institutions now enrolled, and we’re issuing hundreds of

student certifications every year. So we’re quite pleased with the progress we’ve made, and we expect this upward trend to continue. And the list of OEM partners is thriving as well, with companies such as DMG Mori, ROMI, Emco and Levil, among many others, onboard as industry supporters.

Have you seen a shift in recent years within manufacturing, from mere awareness of the shortage of STEM-trained graduates to actually tackling the problem, as Siemens is doing?

Yes, without a doubt. We’ve reached a tipping point where the skills gap is now a mainstream news topic that everyone is aware of, and industry and academia have joined forces to develop effective solutions. We need to convey to students that today’s manufacturing jobs pay $85,000 a year on average and often involve carrying an iPad, not a toolbox. Work/life balance is taken into consideration, and manufacturers are beginning to reestablish apprenticeship programs based on the German model. We want these young people to understand that a four-year college experience might not be for everybody, and that there’s a way to start your life and career after school without being buried under a mountain of debt.

To learn more go to www.siemens.com and search using “CNC4you” for video and other LEAP-related resources.

CUT IT ON A COSEN | www.cosensaws.com INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 15

Safety & Maintenance

Taking an Incremental, Multi-Stage Approach When Upgrading Aging DCS Systems

Addressing gaps, potential risks and islands of automation on a staged basis minimizes costly disruptions to operations and provides greater flexibility as equipment and data needs evolve over time

A

s Distributed Control Systems (DCS) systems age, there can be increased risks to the process manufacturer. An old or obsolete DCS system may no longer be supported by the original supplier, spare parts may no longer be readily available, and system performance issues may begin to appear.

With some DCS systems now decades old, system users often know they need to upgrade but find the task daunting given the cost and potential for disruption of operations while the new system is brought online.

Even if process manufactures have installed newer equipment alongside legacy components, there can be considerable challenges maintaining disparate legacy systems, associated spare parts and the different skill sets required to support multiple control system platforms. This can lead to “islands of automation” that diminish the effectiveness of a user to integrate, control and optimize the entire process from beginning to end. Or it may be the system user has simply outgrown the existing control system due to increased production demands and/or newly added processes.

“Most process manufacturers are looking to maximize their automation investments and run them as long as they can before upgrading or replacing,” explains Dwight Wood, Vice President at NovaTech, a Pennsylvania-based automation provider whose D/3 DCS system solution was introduced 38 years ago as the first hybrid batch and continuous control architecture. “A number of process

|

16 IMD JANUARY 2020

IMD – The Industry’s Most Extensive Industrial Publication

manufacturers have come to us with I/O, controllers and even servers that are 30 to 40 years old.”

When process manufacturers s ultimately decide to move forward on an upgrade, however, they often find that their DCS supplier has implemented a new generation of technology that lacks a cost and mission effective migration path to update the existing system often requiring a rewrite of applications programming or a complete “rip and replace.”

Fortunately, ripping and replacing a dead-ended DCS system is not required.

“Addressing the vulnerabilities that are present with a legacy DCS does not always require a disruptive all-at-once approach,” says Wood. “For a plant of any scale running at or near capacity, taking down processing lines for any amount of time can be extremely expensive in terms of lost production and business impact.”

Instead, many engineering, operations, and procurement teams are opting for a multi-stage implementation over a total system overhaul by phasing in newer DCS servers, controllers and applications. This approach is more affordable and less disruptive, while still allowing gaps, points of pain and cybersecurity risks to be addressed immediately.

A Multi-Stage Approach The process typically begins with a consultation and “deep dive” into the current system and application, said Wood. “We begin the process diagnostically to identify the pain points, gaps, operating

challenges, and any other potential risks in the current process and control system implementation. This supports a more targeted approach that focuses on areas of improvement that can bring the greatest impact in terms of operations and addressing risk exposure.”

A multi-stage migration approach can often begin by integrating new DCS components with new and existing I/O devices. As I/O is one of the most significant investments in an automation upgrade, I/O drops can be replaced in a phased manner over time allowing for spare parts capture from decommissioned drops, phased implementation aligned with plant outage limitations and staggered financial investment.

Another consideration is the need to integrate the DCS system with the existing enterprise systems. “Customers want more than the effective implementation of the Level 2 automation system,” says Wood. “They often want improved data capture and the conversion of that data into useful knowledge presented in desktop KPI dashboards that can be utilized at the manufacturing execution level and/or the enterprise ERP level.”

The User Interface A DCS system is a hub of a processor’s operations monitoring key variables such as flow, applied temperatures, pressure, level and material conveying/handling. The operator user interface brings all the data that is collected from production equipment and the controllers process and presents it in a highly “human factored” manner for an operator, generating trends, alarms, etc.

FASTER SPEEDS. IMPROVED PERFORMANCE. Tormach 1100MX and 770MX.

NEW! Upgrade to the PathPilot Operator Console!

Tormach’s new MX mills feature a BT30 spindle and an encoder for rigid tapping, They’re our most powerful CNC mills yet.

Servo motors provide rapids and cutting feed rates 2.5-3x faster and maximum speeds up to 10,000 rpm.

Combine those improvements with Tormach’s PathPilot CNC Controller (which brings all premium features standard — not hidden behind a massive paywall), MX machines are the highest performing and most cost-effective machining solutions of their size on the market today.

1100MX packages start at $19,995

770MX packages start at $17,995

Build your package today at tormach.com!

INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 17

The NovaTech D/3 interface, for example, displays real-time process information in a complete customeroriented graphical human-machine interface (HMI). Custom graphics, built using dynamic objects from an extensive library, make it easy for the operator to control the process, enter information, and interact with sequence programs.

Standard Operating Procedures, maintenance records, and other information are also available in desktop application formats. The information can be viewed using common Web browsers to display data from multiple plant sites from anywhere in the world.

A Migration Path into the Future A DCS replacement is a significant investment that is designed as a long-term contribution to operations. Two key considerations are the system’s migration path and the overall DCS lifecycle cost.

Whether the search for a control system replacement was caused by system limitations or an existing system being “dead ended” by the supplier, process manufacturers want to avoid this situation happening in the future. When considering a project or supplier, the new system should be scalable, flexible and able to upgrade to future releases on an ongoing basis to leverage system updates and improvements.

The D/3 system, for example, was introduced in the early 1980’s. As a testament to its longevity and flexibility, Wood says the system can still be upgraded with applications written to run on the current version. Hardware has to be upgraded, of course, but a complete “rip and replace” is not required. The company refers to it as an evergreen solution based on its demonstrated commitment to protecting the customer’s migration path.

The total lifecycle cost of ownership needs to be factored in any DCS or control system migration or replacement project. The financial investment in replacing a control system encompasses more than the initial outlay for new hardware, software, and engineering services. Process manufacturers need to also consider recurring maintenance, service support and upgrade costs that they will incur over what can easily be a 20-year or more lifespan.

NovaTech works with its customers upfront to define this cost and provide a system life cycle plan to effectively manage and support the overall investment.

|

18 IMD JANUARY 2020

“A DCS sits on top of an inherently dynamic processing environment made more so as new equipment is added, production lines are expanded, and as issues like obsolescence and cybersecurity present new challenges over time,” explains Wood. “That is easier to navigate if there are a well-defined system life cycle plan and migration path forward that includes a carefully thought-out execution plan for success.”

For more information on DCS platforms, visit the NovaTech website at www.novatechweb.com/process-control/d3-distributedcontrolsystem/ or call (844) 668-2832.

Customized Safety Lifting Devices For Any Application

Safely Lifts Up To 500 lbs!

Ergonomic Portable Lightweight Meets OSHA & ASME Requirements

800-4-SKYHOOK 800-475-9466 • 208-365-5770

www.skyhookmfr.com

The Sky Hook is your personal safety lifting solution, preventing lifting injuries while saving you both time and money!

®

Manufacturing Showcase

EMAG By: Russ Willcutt

F

ounded in Bautzen, Saxony, as an iron foundry in 1867, and eventually relocated to Salach, Baden-Württemberg, in southern Germany, where it branched out into lathes and other specialty machines — and where it is still headquartered today — EMAG is a global entity with a heavy presence in every conceivable industrial market, both geographically and in terms of activity. This includes facilities in China, Japan, Korea, Russia, India, Mexico, and Brazil, among many others, with a host of complementary specialized brands that have been acquired over the years (see sidebar). It established its North American headquarters in 1980, where it oversees operations in the United States and Canada from Farmington Hills, Michigan.

According to Kirk Stewart, vice president of sales, North America, the network for which he is responsible provides insights into the way the company conducts its business around the world. “We take a three-pronged approach,” he explains. “We don’t work through third party sales channels. All the members of our sales team are EMAG employees. First, we have a regional sales force of nine specialists centrally located throughout the United States and Canada. Then we have three key account managers who work directly with our large automotive customers, and finally a

|

20 IMD JANUARY 2020

technical sales force that’s dedicated to electro chemical machining, particularly for aerospace applications.”

This structure is a result of the company’s very DNA, if you will.

From the very beginning, EMAG has been known for its turnkey solutions, working directly with customers to tailor its machine tools to their exact specifications. Taking the United States as an example, in the 1990s through the early 2000s, EMAG was heavily involved with the automotive industry, working closely with OEMs and Tier 1 engineers on design variations that would allow them to meet their production goals in terms of quality, throughput, and technical machine specifications. This hands-on approach remains deeply ingrained the company’s customer service philosophy, Stewart says.

At the same time, market needs shift, and in 2011 EMAG recognized a growing demand for machine tools that could ship quickly, at a lower price point, and therefore within range to a broader field of manufacturers. The machines, known as the “modular standard” line, could be stocked anywhere in the world, are available for immediate shipment, ready to be plugged in and put to work. By 2014, these machine tools were being sold around the world, and EMAG was seeing approximately 30 percent of its U.S. sales coming from operations with fewer than 100 employees; a figure it had never

IMD – The Industry’s Most Extensive Industrial Publication

seen before. This standardization has led to lower build costs for the OEM, and quicker delivery for its customers, among other benefits — making the machines available to a different subset of the market. And the broadening customer base has resulted in new experiences for EMAG with materials including Inconel and titanium. This added material knowledge will be applied to future jobs, expanding the range of EMAG’s expertise.

Another service EMAG provides is a “systems division” that can provide customers with assistance in integrating multiple EMAG machines and technologies, as well as whatever peripheral devices they might need for a custom cell or production line, whether that be a washer, polisher, or marker. If additional components are necessary, the company will offer the customer its choice of third-party OEM for the necessary pieces of equipment, or it will choose from its list of established vendors, in order to deliver a complete turnkey system that is production ready.

Looking to the future, Stewart sees many possibilities for growth, but has seen particular customer interest in the area of lasers. “We have come to find that ‘laser cleaning’ of seams prior to gluing or welding presents a superior alternative to aqueous cleaning, preparing the surface more thoroughly in order to achieve a stronger, more secure bond.

We’re also excited about laser hardening for a number of reasons. First of all, the process really does a good job on parts with complex geometries, penetrating all the angles and channels that other methods might miss, and you also have more control over the exact point or area you’re targeting. This is especially important for thin-wall structures, where the goal is to decrease the overall weight of the part while maintaining strength.”

Whether EMAG is attending IMTS or EMO — or any of the dozens of expos where it’s found around the world each year — Stewart says the company’s capability’s and expertise make it a pleasure to continue to update systems for existing customers and to begin relationships with new ones. “Whether we’re talking about the milling and turning of round parts or the induction hardening of powertrain components, we’re in a position to have a ‘complete process’ discussion, that allows you to perform every necessary operation onsite.

Brands Within the EMAG Group » EMAG: Turning, Milling, Drilling » Reinecker: Internal Precision Grinding » Karstens: External Cylindrical Grinding » Kopp: Camshaft Grinding » Naxos-Union: Crankshaft Grinding » KOEPFER: Gear Hobbing » LaserTec: Joining and Laser Welding » ECM: Electro Chemical Machining » eldec: Induction Hardening » Richardon: Power Skiving

To learn more visit emag.com

INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 21

Workforce Development

Workforce Values and the Strategy of Diversity By: Andrea Belk Olson, MSC and CEO of Pragmadik

T

here's a big push in companies today to create healthy cultures. Many organizations go through detailed processes to identify where culture is going astray and dive into implementing tactics, including defining company values. The problem is too many companies create values without meaning.

Organizational Values Only Work When Tied to Behaviors Written values are often vague and ignored. Many companies have nice-sounding values, such as "integrity", "respect", "communication"

|

22 IMD JANUARY 2020

and "excellence". But these values mean nothing without the behaviors to underline and reinforce them. (As a side note, Enron had those same 'values' displayed in their lobby).

Actual values are behaviors. Behaviors which are true to the organization today, but can also continually improve and grow.

These behaviors have significance to the organization - where without it, the culture wouldn't be the same. These behaviors need to be distinct and genuine - generic values are meaningless.

Take, for example, the value of "excellence". What does excellence mean? How does excellence manifest into a series of

IMD – The Industry’s Most Extensive Industrial Publication

behaviors? How does excellence impact not only customers but employees? What does excellence look like for each and every department? Is it the same or different? What kind of excellence is important (i.e. work quality, work efficiency, etc.)? This is the fundamental problem with generic values - they lack structure, meaning, relevance and most importantly, impact.

Alternatively, think about framing that vague value as a behavior, such as "selflessness". This word has much more meaning. It's something you can do and be. While open to interpretation, uniform examples can be provided to clarify the behavior, such as "be open-minded" and "make time to help others" which provides a broader framework for selfless behavior. This behavior becomes something that can be held up as an example across roles and departments, and even integrated into employee performance reviews.

The real values of a company are shown by who gets rewarded or let go. The real values of a company are reflected in the behaviors of each and every person within the organization. You can't simply create your "values list" and call it a day. Your values shape your organizational culture, your hiring practices, and much more. Values are too important to simply be a display in your lobby. They drive culture, and at their core are behaviors.

IF YOU HAVE AN EDGE… WE HAVE A TRIM! FREE SAMPLES

FREE CATALOG

Test Our Trims and Seals for Quickly View Our Most Popular Fit and Function Lines of Trims and Seals

DESIGN ASSISTANCE Let Us Help You Find the Right Trims and Seals

What's Diversity and Inclusion Without Strategy?

One of the hottest topics in business today is the concept of "diversity and inclusion". Many of the organizations we work with lament about their challenges in this area, stressing their need to "get more diverse" and struggle to build a more diverse workforce. They talk about needing "more representation of minorities" and ask about "recruitment techniques" to help bolster their ranks.

One problem with this is these organizations aren't looking at diversity and inclusion as a strategy, but rather a "checkbox". Do we have folks on our team from this group or that? Yes? Check, check.

This is not the intent of the concept, but rather to bring together a broad set of ideas, perspectives, experiences, cultures, and more - to see and accept things from new lenses to better connect with growing audience diversity.

Another problem is that “diversity” and “inclusion” are so often lumped together that they’re assumed to be the same thing. But that’s just not the case. In the context of the workplace, diversity equals representation. Without inclusion, however, the crucial connections that attract diverse talent, encourage their participation, foster innovation, and lead to business growth won’t happen.

Diversity is being invited to the party. Inclusion is being asked to dance. And diversity alone doesn’t drive inclusion. In fact, without inclusion there’s often a diversity backlash.

Organizations need to think less about "getting diverse" and "being inclusive" and more about understanding the "why", and developing a strategy for diversity and inclusion within their organizational cultures.

While we may think training is the answer, traditional diversity programs often do not work, and recent research shows that they can even have a negative effect on diversity outcomes. That is, they may actually lead to less diversity within the organization. If that’s not bad enough, the training may even reinforce stereotypes about a particular race or gender.

Same Day Shipping on Thousands of Parts

CALL US TODAY!

800-663-9507

HEADQUARTERS MIDWEST MANUFACTURING 6855 HERMOSA CIRCLE 1642 GATEWAY COURT BUENA PARK, CALIFORNIA 90622 ELKHART, INDIANA 46514

WWW.TRIMLOK.COM INFO@TRIMLOK.COM INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 23

Organizations instead, need to focus on culture, defining a strategic plan to build, foster and reinforce the behaviors and mindset of inclusiveness, openness, and equity. Utilizing that strategy with everything from recruiting and retention to organizational communications and collaboration - it becomes your operational framework. Once you can understand the impact, importance and 'why' of diversity and inclusion, it can begin to shape how the organization should behave to achieve those outcomes.

In short, without knowing what you want to achieve and how you plan to get there, diversity becomes yet another

|

24 IMD JANUARY 2020

checkbox exercise with no impact, and inclusion remains the buzzword you bring up once a quarter.

customer-facing operational strategies to

ABOUT THE AUTHOR

on her books, workshops, keynote speeches,

effectively differentiate and build healthy, efficient organizational cultures.

Connect with Andrea to access information training or consulting. More information is also

Andrea's 22-year, field-tested background

available on www.pragmadik.com and

provides unique, applicable approaches to

www.thecustomermission.com

creating more customer-centric organizations.

A 4-time ADDY® award-winner, she began her

Follow Andrea on LinkedIn:

career at a tech start-up and led the strategic

www.linkedin.com/in/olsonandrea1

marketing efforts at two global industrial manufacturers.

PHOTO CREDIT:

In addition to writing, consulting and coaching, Andrea speaks to organizations

Science in HD.

around the world on how to craft effective

Spencer Davis.

AMERICAN-MADE

SHEARS & PRESS BRAKES

HYDRAULIC SHEARS:

1/8” (10GA), 3/16”, 1/4”, 3/8”, 1/2”, 5/8”, 3/4”, 1” and 1-1/4”

PRESS BRAKES:

20-Ton to 1000-Ton

C-FRAME PRESSES:

40-Ton to 200-Ton

CUSTOM DESIGNS:

for Custom Applications

RETROFIT BACKGAUGES:

for Shears and Press Brakes. Made to fit most machines with minimum modifications.

PRECISION KNIFE SHARPENING CALL FOR A FREE CATALOG!

Phone: 319-435-2378 | Fax: 319-435-2262 sales@betenbender.com | www.betenbender.com

Photo courtesy of Dorabot

New Technology

“Cold Turkey” Approach to Robotic Handling By: Michael Castor, Product Manager, Material Handling at Yaskawa America Inc. – Motoman Robotics Division

F

rom highly versatile and portable robots to intuitive robot programming methods, and everything between, emerging technologies are prompting some manufacturers to take another look at robotic automation. While decision makers for these companies agree that jumping into the proverbial robotics pool will most likely save valuable resources and increase production throughput, many leaders confess they have no clear-cut plan for robotic implementation. In fact, it is not unusual in my job to address the following inquiries:

“We Know Our Company Needs Robotic Automation, But Where Do We Begin?”

This is a common question that I receive. Job shops and larger OEMs alike experience pain points. If robotic automation has yet to

|

26 IMD JANUARY 2020

be implemented on the factory floor, it can be an overwhelming concept for decision makers to embrace.

My first piece of advice would be to hold a plant audit. This is where a perceptive robot supplier visits a factory to meet a production team, listen to production supervisors and study how piece parts / goods are manufactured, then packaged for distribution. This process, which can help pinpoint production inconsistencies and workplace hazards, can take several hours to complete and is well worth the time spent.

“So, Where Does Robotic Automation Fit And What’s The Easiest Application To Implement?”

After a plant audit is complete, this is the first question that is typically asked. For companies that approach robotic automation

IMD – The Industry’s Most Extensive Industrial Publication

“cold turkey” (with no specific task in mind), having a consultant help look at the big picture can help highlight production bottlenecks, repetitive tasks and other areas where humans are prone to injury, revealing ideal locations for robotic solutions. From case erecting to palletizing, the best application to implement on a production floor will vary from one company to the next, but here is a general idea of the most popular handling tasks that get automated and their perceived levels of complexity:

EASIEST: Palletizing: Often the best place for manufacturers to start robotic implementation on the production floor, the relatively simple process of robotic palletizing usually includes moving uniform boxes that are already loaded from one point (i.e., conveyor) and stacking them on a pallet for shipping. Likewise, the motion performed is repetitive, making it the perfect application for an industrial robot.

The task of programming a palletizing operation can be simplified through easy-to-use software, such as PalletSolver®. This enables users to generate even the most complicated package and pallet layouts offline and load them onto the robot controller when required.

Pick & Pack: Thanks to fast and highly-capable robot arms, like the GP7, GP8 and GP12 robots, the use of robotic automation for picking and packing is growing in popularity. Great for taking the trays generated

from pick and place, or loading singulated or grouped items into bigger cartons, picking and packing can also be a good place for companies to start robotic implementation. However, it is important to keep in mind that while picking and packing can be done using clever conveyor and tooling designs for uniform products, it can be complex if sortation or mixed items are required.

MODERATE: Pick & Place: Delta-style robots are good at taking individual items and placing them in trays for further packaging down the line. This is ideal for

Are you still using welded nuts or inserts?

Replace with Formdrill! #NoNuts Formdrills form sturdy bushings that can be threaded to produce your own inserts. These built-in inserts are as strong or stronger than the same-diameter welded nuts.

Process works in steel, stainless steel, copper and aluminum up to ½” thicknesses. Standard UNC, UNF, NPT and Metric sizes are available up to 1.5” in diameter.

It can easily be used in most Drill Presses, Milling Machines and CNC systems. Ideal for Automated Production Lines.

FORM

YOUR OWN

INSERTS WHAT OUR CUSTOMERS SAY:

“ We reported a $45,000 savings the

first year of use after switching to Formdrill. ”

“ Formdrills did 8,144 holes compared

38 YEARS EXPERIENCE IN THERMAL DRILLING COSTS ABOUT 1 CENT PER HOLE

to 1,300 with the competition. ”

WWW.FORMDRILL-USA.COM

FORMDRILL USA 773-290-1040 info@formdrill-usa.com

INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 27

packaging small goods (i.e., cosmetics), parts or even food that needs placed into a holder of some sort. Pick and place robots utilize advanced user-friendly software packages, like MotoPick™, allowing for the development of machine vision-based, high-speed picking. This software and vision system combination provides manufacturers with the building blocks to create optimal solutions that can identify, orient and place an object into a tray or on a conveyor with speed and precision with minimal human interaction.

Moderate in difficulty, this process involves layout modifications – including some way to “hang” the robot – conveyor tracking, vision setup, tool design and more.

Case Erecting: Traditionally achieved manually or by hard automation, case erecting can be optimized by adding a versatile robot arm, giving manufacturers the flexibility needed for frequent box changes in a high-mix, low-volume market. While some hard automation may still be used for actions such as box loading or case sealing, a robot equipped with 2D vision and a customized end-of-arm tool (EOAT) can easily detect box sizes and adjust accordingly, allowing the robot to set up a variety of boxes without further intervention.

COMPLEX: Sortation: Often considered the “holy grail” of unloading – especially in the logistics market – one of the most complex applications to automate is having a robot pick up and sort unstructured, mixed objects. Even if items arrive at the robot in a singulated manner, massive variation of object heights, sizes and materials can make it difficult for a robot to perform dynamic picking tasks. While a perfect solution does not yet

|

28 IMD JANUARY 2020

exist, companies such as Dorobot and PlusOne Robotics are working to blend 3D vision systems and AI software with robots to solve unique applications in real time, allowing the robots to pick up objects quickly and reliably with minimum human intervention.

Depalletizing: The task of unloading a pallet is relatively simple if the products arrive on uniform pallets with uniform box sizes, but this is rarely the case. Because the process of unloading tends to be a bit more complex due to variability, the utilization of a high-performance vision system is often required. Equipped with a 3D vision system that utilizes 3D CAD matching software, an industrial robot arm can determine the length, width and height of the boxes being unloaded.

This ensures the reliable unloading of packages and proper placement for further processing. Companies, such as Wynright, specialize in creating order from this type of “chaos”, offering unique solutions to address complex and monotonous unloading tasks.

“What should be our next step?”

If you have found yourself nodding in agreement to the scenarios presented, or if these six applications have sparked an interest for robotic automation on your factory floor, the next step should be to contact a robot vendor that is knowledgeable on a wide range of solutions to conduct a thorough plant audit. It is equally important to find a supplier or integrator that is dedicated to complete customer satisfaction at every stage of the project life cycle. This will help to smoothly transition your company into the world of robotic automation and a viable path to profitability.

For more information, visit www.motoman.com

Fastest, Most Accurate Bar Puller On The Market Watch the video now at: ezpullerusa.com • NO MECHANICAL ADJUSTMENT NECESSARY (X axis end point gets changed in the program when changing bar diameters) • ONE TIME SETUP • NEVER NEEDS ADJUSTMENT •CHANGE BAR SIZE IN SECONDS (BY CHANGING “X” VALUE IN PROGRAM) • EXTREME REPEATABILITY RESULTS IN LESS MATERIAL WASTED PER PART • NO GRIPPING FINGERS TO ADJUST, LOSE OR BREAK • EZ-PULLER WORKS ON ROUND, HEX AND SQUARE STOCK. RANGE: .093″ – 1.750″ ROUND STOCK .125″ – 1.375″ HEX STOCK .125″ – 1.000″ SQUARE STOCK

by

60 Day Money Back Guarantee 2 Year Warranty!

“Absolutly, no time.

Zero time adjusting the tool.”

- Randy, CNC Lathe Programmer

303.991.1500

Process

LASER CUTTING vs.

WATER JET CUTTING: Knowing the Difference and When to Use Which

L

aser cutting and water jet cutting—as a manufacturer, you likely already know what both of these are, or have maybe even used them in your own business. While both processes have been around for a few decades now, they are both considered relatively new, and only continue to grow in popularity.

Technology has made significant progressions in both laser and water cutting machines over the years. As a result,

|

30 IMD JANUARY 2020

Leverwood Knife Works is excited to already be a cut above the rest by implementing a new laser cutting machine into our workflow processes. In this post, we want to go over laser cutting and water jet cutting and show you why we chose to go with laser cutting to help improve our products.

How Does Laser Cutting Work?

If you’re picturing laser beams or lightsabers from science fiction, you’re actually not too

far off. Have you ever taken a magnifying glass out in the bright sun and burned a small hole in something with it? Using a concentrated beam of light as you do with a magnifying glass, is actually how laser cutting works.

A laser cutter takes a laser beam—“a column of very high-intensity light of a single wavelength” invisible to the naked human eye—and using mirrors, refocuses the beam so it concentrates into a single

M

ADE IN TH

E

USA

100%

The Best Tool Cabinet You Will Ever Buy GUARANTEED IN

E V E R Y W AY

MADE BY AMERICAN CRAFTSMEN IN THE USA

WWW.STORLOC.COM • 1-800-STORLOC 1-800-786-7562 sales@storloc.com

pinpoint. By focusing the laser, the light becomes superheated in one spot and cuts objects as close as .006 inches (depending on cutting speed).

What Are the Advantages of Laser Cutting?

There are several reasons as to why laser cutting has become so popular and common in the last few years, mostly due to its advantages in lowering lead times. At Leverwood, we use a new state-of-the-art CNC laser metal cutting machine. This new laser cutting machine makes more precise cuts than other equipment and creates even more accurate blades. Here are a few reasons why we recommend taking advantage of laser cutting services.

Metal Combinations with Different Melting Points If your project has two or more types of metal combinations, you have to take into consideration if each metal has a different melting point. If so, you may not get the precision or results that you’re looking for.

Can’t Cut Highly Reflective Metals When cutting highly reflective materials, a laser metal cutting machine may not be your best route. Materials like copper, bronze, brass, aluminum, gold, and silver and can reflect up to 95 percent of visible light. Since laser cutting uses light and mirrors, the reflecting can cause problems for cutting.

Incredible Precision

How Does Water Jet Cutting Work?

More precise than its waterjet cutting counterpart, laser cutting is where you’ll want to turn to for finely detailed projects. As we mentioned earlier, laser cutting can cut as small as .006 inches, while waterjet cutting only goes to .02 inches.

Now that we’ve gone over exactly how laser cutting works, we’ll discuss another popular cutting method—water jet cutting.

If you’ve ever been at the wrong end of a high-power hose or pressure washed the side of a house, you’ll already have a vague idea of what water jet cutting is. Water jet cutting takes extremely high pressures of water that are concentrated into a single stream to cut various materials. Next to laser cutting, water jet cutting is the next most precise way of getting finely detailed and accurate cuts on your materials.

Lower Risk of Contaminating Materials Laser cutting offers the advantage of not having the cutting tool come into direct contact with the material. Depending on how sensitive the material you’re working with is, that can be a huge advantage. Without that tool-to-material contact, there is a much lower risk of contaminating your material.

Lowered Risk of Deformation While a lot of common materials need heat to be cut, a lot of the times, the material can melt and cause deformation. When you use laser cutting for your project, the heated area is so small that you significantly reduce possible distortion in your materials.

What Are the Disadvantages of Laser Cutting?

There are a lot of advantages to utilizing laser cutting services, but it may not be ideal for every single project. There are a few times where you may need to turn elsewhere when you need your materials cut with accurate precision.

|

32 IMD JANUARY 2020

What Are the Advantages of Water Jet Cutting?

Just like laser cutting, water jet cutting is an extremely accurate manufacturing process. As we mentioned earlier, water jet cutters can cut sizes as small as .02 inches. Here are a few more of its well-known advantages.

Cuts Almost Any Material Water jet cutters can cut almost any material that traditional cutting methods can, as well as a few more. Whether it’s stone, metals, or glass, there aren’t many materials that water jets can’t cut. The only few materials a water jet cannot cut are diamonds (they’re too hard), tempered glass (too fragile), and a few types of advanced ceramics or composite materials for various reasons.

No Heat Produced

Less Accuracy with Thicker Materials

Remember one of the issues we mentioned previously about laser cutters sometimes having problems with melting materials that have different melting points? This is where water jets come to the rescue.

Since water jet cutters use significantly less heat and don’t overheat any areas close to where you’re cutting, your materials remain intact and undamaged.

When you use water jet cutting, the area closest to the stream of water is going to receive the most force. Because of this, thicker materials can sometimes cut less accurately since the stream is further away from the point of impact. The result is that the cuts sometimes look slightly more diagonal than giving a clean, straight line.

Potential for More Risks and Noise Pollution Considered “Green Technology” Because water jet cutters use…well, water, to cut materials, these machines do not create any hazardous waste. It also allows for scrap metal to be recycled and uses very little water when cutting.

What Are the Disadvantages of Water Jet Cutting?

While this method of metal fabrication is still commonly used, there are a few disadvantages to water jet cutting that we want to bring up.

It’s because of these reasons (and a few others) that have Leverwood consistently turning to laser cutting almost every time.

Like with most metal fabrication or industrial processes, anyone that operates a water jet cutting machine needs to be conscious of the safety risks. Ear protection will be required due to the surprisingly high noise pollution that it causes, as well as eye protection (both of which are not always necessary with laser cutting but still recommended).

ABOUT LEVERWOOD KNIFE WORKS Looking for the Best Blades and Cutting Processes for Your Business?No matter what you need cut, you can rely on Leverwood Knife Works to

Much Longer Cutting Time

provide you with the most precise, custom, and standard industrial knife

One of the biggest reasons we love our laser cutter is that the machine loads and unloads material automatically and cuts much faster than any other method. When we can cut faster, we can afford more capacity for projects and get our customers a much quicker delivery time. Water jet cutting is slower than the laser cutting method, and we’re always looking to work as efficiently as possible.

blades on the market. Leverwood blades are produced using only the best materials and processes available to ensure your blades are durable and accurate. Maximize your efficiency and contact Leverwood for more information on what they can do for you and your business.

For more information, visit www.leverwood.com

NO LONG LEAD TIMES. NO WAITING.

JUST ON-THE-SHELF AVAILABILITY.

MAXIMIZE UPTIME AND MINIMIZE MAINTENANCE COSTS We offer a wide variety of units and components ranging from piston pumps, vane pumps, valves, servo/proportional valves, orbital motors and replacement parts. Many units are in stock and ready for immediate delivery. Whether you’re looking for a new replacement unit, reman unit or a repair, we can help you save money and maximize uptime with our vast on-the-shelf inventory and quick turnaround on repairs.

Make Hydraulex your first call when you need replacement hydraulic pumps and motors for your equipment.

1.800.422.4279 sales@hydraulex.com

www.hydraulex.com

www.ahx1.com

INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 33

Industry Insight

Improved Machining Solutions – Today

Servicemold + Aerospace Inc. Tracks Growth From Zimmermann Milling Machines

F

ounded in 1987 in Windsor, Ontario and today run by President Martin Schuurman, ServiceMold + Aerospace is not your typical mold shop. While the core competence remains the design, engineering and building of injection, compression, low-pressure, blow, glass-encapsulation and forming molds for the automotive industry, the company has emerged as a contract, buildto-spec supplier of parts for that industry as well as aerospace and medical customers in North America and Europe.

The early years saw steady growth from the production of molds for automotive and consumer goods. Always committed to using the latest technologies for CAD and CAM programming, as well as state-of-the-art 3-axis machine tools, ServiceMold established a reputation for quality work, problem-solving and on-time delivery, quickly becoming a reliable partner to their customer base.

Then, our industry changed.

|

34 IMD JANUARY 2020

As Schuurman explains, “In 2006, we purchased our first 5-axis machine, a Zimmermann with a 2 x 3 meter (78” x 118”) table. This acquisition gave us the ability and capability to explore entering the aerospace market. After a number of calls and quotations, we scored a small order from a major Tier 1.” Sales began to grow, some years by more than 25%, Schuurman says proudly. By 2013, there were four additional Zimmermann machines on the floor and the existing facility had filled nearly to capacity.

The company acquired property adjacent to the current facility in Windsor and erected a new building in 2016, giving the company a capacity of 64,000 square feet. They purchased three Zimmermann FZ33 milling machines, two with 394’’ in the x-axis and the largest one, with 630” x-axis, 138” y-axis and 78” z-axis, giving the shop a substantially greater workpiece capability and opening up more opportunities in the aerospace structure market.

IMD – The Industry’s Most Extensive Industrial Publication

In something of a perfect storm scenario, the emergence of composites in the aerospace industry enabled Service Mold to pursue the huge layup mandrel market to a much greater degree.

Always thinking strategically, Schuurman had an early ongoing commitment to pursue and maintain full certification or registration as an ISO, AS9100 rev D, CGP and ITAR facility, all of which are in force today. “We quickly realized what it would take to continue proving our worth in all the various industries and we went after those certs with a great determination.”

Likewise, the company introduced more machining capabilities plus welding and today is exploring the benefits of in-house heat treatment to max up its vertical integration. Such capital investment comes with risk, Schuurman notes, as the dual challenge of finding competent personnel combined with the need to generate sufficient workload to fill the available machining time, which today stands at approximately 15,000 hours annually on the seven Zimmermann machines alone.

As the company currently runs roundthe-clock operations, it would appear the investment is paying off.

Never one to rest on his laurels, however, Schuurman explains, “We are a build-to-print company for our customers.

By definition, that means we’re always on the hunt for more business and we’ve expanded our component production work substantially, in addition to producing more complex and larger molds and fixtures for our customers.”

He also takes great pride in a satellite business he’s developed, over the years. An artistic individual, Martin Schuurman designs custom air vent designs and manufactures the molds to produce them in quantity.

What started out as a hobby to decorate his own and family members’ home has blossomed into a thriving business for him.

It operates as SMI Ventilation Products, with primarily online sales done through several key distribution customers.

ServiceMold utilizes the Zimmermann and other machining centers to produce molds and components from various alloys

of aluminum, steel, Invar and stainless. The twin facilities house boring mills with rotary tables, gundrills, CNC milling machines, 3-axis high-speed mills and, the core of the company’s machining firepower, seven Zimmermann and two Parpas Diamond 5-axis high-speed machining centers.

At the high end of the Zimmermann lineup are machines with the company’s unique portal milling head, plus an FZ33 Compact, which allows large aluminum and composite structures to be machined without moving them, as the workpiece rests on a fixed table, while the rigid portal

INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 35

travels in the x-direction. The moving bridge on the machine comprises a rigid portal, cross- and z-slides plus the milling head.

Additional Zimmermann machines on the floor at ServiceMold include three FZ37 5-axis portal milling machines and three FZ30 open table 5-axis portal milling machines, ideal for the one-off and short run work done so often at Service Mold.

Also in-house here are a CMM with 30,000-pound load capacity and ion laser tracker for the large workpiece scanning done on the floor of the facilities here. All data can be captured in a point cloud and instantly analyzed against the CAD files for accuracy and stress points.

Another emerging market for ServiceMold is the orthopedic industry, where the high accuracy of the Zimmermann machines in Aerospace inspired the company to venture into medical device machining. “We’re currently working with an orthopedic surgeon, producing joining plates for humerus and femur sections, something we’d never have considered a few years ago. With the programming speed and high degree of flexibility in our production work now, it’s not only become possible, but also profitable,” he muses.

Still, the home base, with over 70% of the sales for the company, remains the aerospace market, including a favorite project for Martin Schuurman, one he describes with great excitement. “We have been involved in manufacturing parts for servicing the International Space Station.” As happens with most workpieces in this market, there is an extremely high degree of material removal involved

|

36 IMD JANUARY 2020

in the production of this workpiece and Schuurman notes the Zimmermann machine rigidity and high-precision moving milling head make the job much easier to accomplish and repeat.

Cornelius Kiesel, president of Zimmermann for North America, with its headquarters located across the river from Windsor in the greater Detroit area (Wixom, Michigan) comments, “We have forged a solid, good faith working relationship with ServiceMold since that first sale in 2006. Today, ServiceMold is one of our largest customers in the world. Zimmermann has other customers like Martin Schuurman and our machines were a perfect fit for his requirements, plus they offered some added advantages that have helped ServiceMold move into other markets and other types of jobs, over the years. When you can partner with a customer and grow together, there are few satisfactions in business that compare.

It’s a very solid relationship and we’ve been quite pleased with the results. Martin brings our team new challenges all the time and we respond. The synergy between our companies and their respective talents makes something very special happen and that’s exciting,” Kiesel notes. Schuurman adds, “Our partnership with Zimmermann has brought about many expectations over the years and Cornelius and his team have delivered for us.”

As a further testimony to the value of the Zimmermann machines at ServiceMold, Kiesel notes his customer has recently rebuilt the original machine purchased, retrofitting a new milling head design, among other mechanical and controls upgrades.

ACTEK HOIST RINGS Pi

0° 18 ts vo

Schuurman notes in particular that the linear motor movement and high-speed spindles on the machines are key benefits in the precision machining of aluminum with substantial metal removal rates.

Among the many and varied components produced at this shop, in addition to the myriad molds created each day, are refrigerator trays, washer lids as well as a 22” barrel inlet for aircraft engines, which starts as a 23”diameter aluminum block, usually 15-16” high that has material removed to reduce the piece to less than 5 pounds.

As Schuurman point out, a key to the flexible nature of his company is the fully programmable capabilities of the Zimmermann machines.

“We’ve worked very hard over the years to carve out some unique niches for our shop and we have a very solid reputation in various industries. That’s given us great pride and, on a practical note, greater stability and protection from the economic volatility in certain vertical markets.”

ServiceMold runs various CAD programs, including Catia and NX CAD, post-processing in-house to run the Heidenhain CNC on each of the Zimmermann machines here. Weekly certification of the machines onsite, with volumetric compensation calculation done.

Service Mold is AS9100 Rev. D and ISO 9001:2008 Certified, Controlled Goods Program Registered and ITAR Compliant.

200% PROOF LOAD TESTED EACH RING HAS SERIAL NUMBERS ORDERS SHIPPED SAME DAY RATED LOAD 400 LBS - 250,000 LBS Forged Street Plate™ Swivel Hoist Rings

Side Load Hoist Rings

Hoist Ring Kits

Mold Handler™ Swivel & Pivot Hoist Rings

Forged Swivel Hoist Rings

Round Base Swivel & Pivot Hoist Rings

Swivels 360°

Drop Forged Hoist Rings

For more information, please contact:

SERVICE MOLD + AEROSPACE INC. Martin Schuurman, President 2711 St. Etienne Blvd.

Windsor, ON N8W 5B1 Canada Phone: 519-945-3344 Web: www.service-mold.com moldsales@service-mold.com aerosales@service-mold.com

ZIMMERMANN, INC. Cornelius Kiesel, President 30587 Century Drive Wixom, MI 48393 USA Phone: 248-305-9707 Web: www.zimmermann-inc.com sales@zimmermann-inc.com

ISO 9001

ACTEKMFG.COM

800-752-7229 | SALES@ACTEKMFG.COM

SAFE & EASY LIFTING SOLUTIONS INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 37

On Exhibit

Pacific Design & Manufacturing DATES: FEBRUARY 11–13, 2020 Location: Anaheim Convention Center | Anaheim, CA If you are searching for innovations in CAD/CAM software, Rapid Prototyping, 3D Printing, and the latest in precision machining technology, the Pacific Design & Manufacturing show is for you. Attendees can benefit from five co-located shows, featuring more than 1,900 exhibitors this February in Anaheim, California. » For more information, visit pacdesignshow.designnews.com

EXHIBITOR HIGHLIGHTS..................................................................................

BOOTH: 4411

ATI’s Small and Mighty Automated Tool Changer QC-11 The QC-11 enables automatic exchange of robotic end-effectors without any manual intervention. With an ATI Automatic Tool Changer, a robot can utilize multiple end-effectors in a single process. Preceding the QC-11 in the UR+ program are ATI’s Axia80 Force/Torque Sensor and MC-10 Manual Tool Changer. The QC-11 was the first automated tool changer developed in the Americas to obtain UR+ certification. ATI’s patented, pneumatically-actuated, fail-safe, locking mechanism provides strong, repeatable coupling under the rigors of industrial use. It also ensures that the tooling remains securely attached to the robot—even during a loss of air pressure. »

For more information, visit www.ati-ia.com

BOOTH: 5014

Dorner’s FlexMove Conveyor Platform Represents a Merger Between Two Existing Product Lines While the FlexMove name isn’t new to Dorner, it now incorporates the features and strengths of the former SmartFlex conveyor line. FlexMove conveyors are available in three purchasing options based on the customer’s application and situation. With FlexMove Components, customers can order all the necessary parts and components to build their FlexMove conveyor onsite. These aluminum-frame, flexible chain conveyors are ideal when floor space is limited as they are designed to make tight 360-degree turns in and around machinery and equipment. »

For more information, visit www.dornerconveyors.com

BOOTH: 4282

Festo Now Distributing Magswitch Magnetic Gripping and Clamping Solutions Festo now offers Magswitch switchable magnetic gripping and clamping solutions to automotive and original equipment manufacturers (OEMs) through a new distribution agreement. Magswitch automation solutions are designed to last the life of a production line. The company has shown that energy costs can be lowered by as much as 90 percent, throughput can be increased by up to 30 percent, and capital costs reduced as much as 25 percent compared to systems using vacuum cups and pneumatic/electric grippers or clamps.

Magswitch offers single sided gripping systems featuring true on-and-off magnetic technology that can significantly simplify and lower costs of complete automation systems in OEM assembled lines in such applications as robotic welding, pick-and-place, and body-in-white. »

For more information, visit www.festo.us

|

38 IMD JANUARY 2020

IMD – The Industry’s Most Extensive Industrial Publication

BOOTH: 3413

Flexible and Robust 3D Metal Printing With DMP Flex 350 A robust, flexible 3D metal printing solution for 24/7 production of parts up to 275 mm by 275 mm by 380 mm in size, the DMP Flex 350 is the successor to 3D Systems’ ProX® DMP 320 3D metal printer. Ideal for application development, production, and research and development, the DMP Flex 350 ensures high quality and productivity with its integrated 3DXpert® software, thoroughly qualified LaserForm® materials and expert application support. Thanks to its improved gas flow technology, this solution ensures improved, uniform part quality across the entire build area – even for parts made with the world’s most challenging alloys and extremely dense, pure metals. »

For more information, visit www.gfms.com

BOOTH: 4439

QC20-W Ballbar System Renishaw ballbars have led the market for nearly 20 years and that leadership continues today with the QC20-W wireless ballbar system. The Renishaw QC20-W ballbar system consists of the ballbar itself (essentially a very high accuracy, telescoping linear sensor with precision balls at each end) and two precision magnetic mounts, one attached to the machine table and the other to the machine spindle or spindle housing. In use the balls of the sensor are kinematically located in the magnetic cups. This arrangement enables the ballbar to measure minute variations in radius as the machine follows a programmed circular path around the mount on the machine table. »

For more information, visit www.renishaw.com

SHOWA LUBRICATORS AND ACCESSORIES

SHOWA Centralized Lubrication Systems • Automatic lubricators and cyclic lubricators.

• Manual and pneumatic pumps.

• Volumetric lubrication systems.

• Resistance lubrication systems.

• Progressive lubrication systems.

• • • •

Lubrication injectors for oils and greases.

Oil-Air lubrication systems.

Spray systems.

Fittings and accessories.

30 Front Street • Belchertown, MA 01007 • Phone: (413) 323-9041 • Fax : (413) 323-9595 www.rasmachinetool.com • sales@rasmachinetool.com INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 39

On Exhibit

HOUSTEX DATES: FEBRUARY 23–25, 2019 Location: George R. Brown Convention Center HOUSTEX once again returns to Houston, February 23-25, at the George R. Brown Convention Center. The show will bring an exciting mix of manufacturing products, services, and intel highlighting the latest advanced technologies and processes that are disrupting industrial sectors important in the Gulf Region and helping manufacturers prepare and reshape their enterprises. » For more information, visit www.houstexonline.com

EXHIBITOR HIGHLIGHTS..................................................................................

BOOTH: 2108

GEN3SYS XT Pro Structural Steel Insert Withstands The Heat And Extends Tool Life While Allied’s entire XT Pro product line thrives in high-penetration drilling applications, this unique combination of carbide grade, geometry and high-temperature coating is designed to run at or beyond current O.E.M. rates in structural steel applications. The insert’s simplified setup and extended tool life reduces changeover and increases throughput. Their upgraded carbide insert has been completely redesigned to improve throughput and cut operational costs by extending life and increasing penetration rates. With a proprietary blend of substrate and multilayer AM420 coating, the insert is composed to withstand the extreme heat produced while drilling in structural steel beams or plates in high production facilities. »

For more information, visit www.alliedmachine.com BOOTH: 1206

Introducing Powerfoil D: The Industrial Direct-Drive HVLS Fan Perfected Big Ass Fans has unveiled Powerfoil D, the product of 10 years’ experience and purpose-built design. The exceptionally engineered Powerfoil D is the first and only direct-drive overhead fan designed for harsh industrial environments. Powerfoil D illustrates the company’s continued commitment to building premium-quality products specifically designed for customer spaces.

Powerfoil D delivers strength and performance required for industrial applications, but with virtually silent operation and aesthetic appeal to thrive in any commercial or public setting. »

For more information, visit www.bigassfans.com

BOOTH: 2012

The Next Generation of VERICUT - Version 9.0 Irvine, CA - CGTech is pleased to announce the latest release of VERICUT software, Version 9.0. VERICUT CNC machine simulation, verification, and optimization software simulates all types of CNC machining, additive, and hybrid manufacturing processes. The software operates independently, but can also be integrated with leading CAM systems. VERICUT 9.0 features several enhancements designed to increase power and improve efficiency, including a new graphics engine. Users will experience sharper, clearer and more realistic views of machines and the machining process. VERICUT 9.0’s greatly enhanced image quality makes it easier to spot problems and imperfections in machined parts. »

For more information, visit www.cgtech.com

|

40 IMD JANUARY 2020

IMD – The Industry’s Most Extensive Industrial Publication

BOOTH: 1506

XPS-16+ CNC Drill Sharpener Designed for shops that demand precision, the XPS-16+ grinds complex geometries with the touch of a button quickly and accurately. The XPS-16+ Automatic 4-axis CNC Drill Sharpener and Grinder is an extremely accurate work horse for high tech applications. The XPS-16+ is for shops that demand the ultimate in precision, simplicity and productivity. The XPS-16+ can do it all - with the touch of a button. Assembled in the USA. Point styles sharpened include standard conic, 4-facet, standard and radius split point. Darex offers in-house training, and 60-grit and 320-grit diamond wheels, 120-grit hone brush, as available options. The XPS-16+ includes a one year warranty. »

For more information, visit www.darex.com

BOOTH: 1435

Automatic Vertical Band Saw from Hydmech The V-18APC-60 is an automatic vertical band saw with the ability to miter from 60° left to 60° right. The V-18APC is fast, with its high speed shuttle feed indexing up to 40" in a single movement. A 2 HP driven hydraulic pump supplies system pressure through 3-position directional valves controlling all vising, head swing, head advance/retract, blade tension, guide arm, and shuttle movement. Its PLC control features storage of up to 1000 jobs with the ability to run 5 in queue. Featuring a 18"W x 22"H capacity, 7.5 HP motor, and 1 1/4" blade, the V-18APC is a reliable choice for all your vertical metal cutting applications.

For more information, visit www.hydmech.com

PHOENIX C I N C I N N AT I ORLANDO S E AT T L E W I C H I TA S T. L O U I S HOUSTON S A LT L A K E C I T Y DETROIT

Register Today! www.amconshows.com

800.829.7467 FREE

»

ADMISSION ATTENDEE PARKING SEMINARS

AmCon-HH-01-2020.indd 1

3D PRINTING DESIGN ENGINEERING PROTOTYPING MACHINING CUTTING GRINDING

FORMING FABRICATING RUBBER PLASTICS COMPONENTS CASTINGS MOLDS

TOOLS DIES PATTERNS FINISHING ASSEMBLY FIXTURES ELECTRONICS

...AND MUCH MUCH MORE.

See Manufacturing’s Latest Cutting-Edge Technologies at ANY of Our Upcoming Shows Spring 2020

Phoenix, AZ .............................................................. March 4-5, 2020 Cincinnati, OH ...................................................... March 18-19, 2020 Orlando, FL ..................................................March 31 – April 1, 2020 Seattle (Tacoma), WA .............................................. April 28-29, 2020 Wichita, KS.............................................................. May 12-13, 2020

Fall 2020

St. Louis, MO ..........................................................September 15-16 Houston, TX ................................................September 30-October 1 Salt Lake City, UT ........................................................ October 21-22 Detroit (Novi), MI .......................................................November 17-18

|

IMD 41

12/23/19 12:05 INDUSTRIAL MACHINERY DIGEST.COM

PM

BOOTH: 1635

Increased Slide Travel for Gundrilling Machine The Eldorado M75-48T is a two-spindle gundrilling machine with 48 inches (1,219 mm) of slide travel. This is 60 percent more slide travel than the standard Eldorado model offered by the company. The additional length allows the machine to accommodate nearly all the gundrilling applications a job shop will encounter. It features two gundrilling spindles with independent spindle control, allowing two different drilling cycles at the same time. The machine also utilizes counter-rotation of the workpiece to improve drilling performance. Eldorado gundrilling machines are designed and manufactured by Kays Engineering in their Marshall, Missouri, USA facility. »

For more information, visit www.kays-dehoff.com BOOTH: 2413

MC Machinery Systems Launches New Small Electric Press Brake The BB306 is a fully electric press brake is designed with a smaller footprint to fit any facility and form smaller parts. The new machines come with the same standard features customers have come to appreciate and expect from MC Machinery; including an integrated all axis pulse handle, thickness detection, multi-axis back gauge, front and back LED lighting, and the largest user-friendly control in the market. Additionally, the BB306 comes with the new MOS control found on all BB and BH series and 100% Mitsubishi electronics, motors, and servo drives featuring an AC Servo motor and ball screw drive mechanism. »

For more information, visit www.mcmachinery.com Booth: 2949

agro-hytos hydraulic products

filtration… The range of filter solu-

tions implemented at Argo-Hytos extends from fixed-position industrial plants to highly mobile applications, primarily tailored to individual customer requirements. As a result of their vast experience with custom applications over a wide variety of sectors, Argo-Hytos offers a comprehensive range of innovation standard solutions: Suction Filters; Return and Return-Suction Filters; Pressure/ High Pressure Filters; Filling and Ventilating Filters; Filter Accessories; Sensor Technology.

fluid and motion control…

Directional control ValVes D02/D03/D05/D07/D08: Argo-Hytos DC and dual frequency AC coils can be rotated to locate connectors to your need. DIN, Deutsch Flying Leads and Wire Box Connection are available as standard Manual Override. Full line of Sandwich Controls.

FiVe series oF ValVes rate to 5000 Psi: RPE3-04, providing 8.0 GPM; RPE3-06, providing 21.0 GPM; RPE4-10, providing 37.0 GPM; RPE4-16, providing 80.0 GPM; RPE4-25, providing 160.0 GPM Gear PumPs: Argo-Hytos gear pumps provide high reliability, high volumetric efficiency, and low noise levels over the entire operating range. three series: GP1-P, maximum pressures from 2300-4350 flows 1.0 gpm; GP1-T, maximum pressures from 1700-4200, flows 1.0 to 17.0 gpm; GP1-Q, maximum pressures from 29004500, flows 7.1 to 42.8 gpm.

7355 N. Lawndale Ave., PO Box 6, Skokie, IL 60076

Phone: 847-676-2910 Fax: 847-676-0365 www.macmhydraulic.com

|

42 IMD JANUARY 2020

The Leading MRO and Automation Solution Radwell International stocks and sells New and Surplus Industrial Automation, MRO, pneumatic, motion, electronic, hydraulic, HVAC and Electrical Control Equipment for plant floor and facilities maintenance machinery. They also have full component level repair capabilities for all industrial electronic and electrical equipment. Radwell International gives you a 2-year warranty on every item they sell and on every repair they do. The free 2-year warranty makes every Radwell purchase a dependable, reliable investment in your company's future. Radwell also buys Surplus Industrial Controls. »

For more information, visit www.radwell.com BOOTH: 3015

Starrett Introduces Automated Digital Hardness Testers The L.S. Starrett Co., has introduced two new digital Rockwell/ Superficial Rockwell Benchtop Hardness Testers (Nos. 3823 and 3824) with fully automated load/ unload procedures, and capable of providing highly accurate readings. The new Starrett Hardness Tester models utilize a closed-loop control unit with a load cell, a DC motor and an electronic measurement and control unit instead of traditional dead weights, enabling high accuracy measurements at all test loads up to 0.5 percent. The testers are part of a significantly expanded line of new hardness testing solutions that Starrett is now offering. »

For more information, visit www.starrett.com

BOOTH: 2503

SV-15 cylinder hone updates a proven mechanical design with a Siemens control Sunnen's SV-15 honing machine combines the DNA of the legendary Cylinder King machine with a Siemens touchscreen PLC to provide more features, convenience, and even greater precision and consistency than the "King" of motorsports honing. A real-time display of the bore shape allows the operator to confirm bore straightness and make on-the-fly adjustments to correct taper – or simply confirm the action of the auto-dwell feature that efficiently concentrates honing action in tight spots. The control automatically switches from roughing cycle to finishing cycle for fast processing with the optimum finish, geometry and crosshatch angle. »

C-FRAME PRESSES

For more information, visit www.sunnen.com • Heavy Gauge Steel Design • Press Bed bolted on, not welded, to prevent distortion.

• Large press bed to accommodate a variety of tooling other than just punching.

• Pump, motor, valve and reservoir are all easily accessible for maintenance.

• Large rectangular tubes used at base of machine to give safe, instant portability.

WE CAN BUILD A CUSTOM MACHINE FOR YOU!

5806 Quality Ridge Rd | Coggon, IA 52218 Phone: 319.435.2378 | Fax: 319.435.2262

www.betenbender.com INDUSTRIAL MACHINERY DIGEST.COM

|

IMD 43

Product Showcase

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

IMD's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

1/8 NPT Siphon Fed Spray Nozzles for Non-Pressurized Liquids EXAIR's new 1/8 NPT siphon fed spray nozzles atomize fluids in a range of spray patterns for a wide variety of uses. These are EXAIR’s smallest air atomizing nozzles and are suitable for tight spaces. Siphon fed atomizing nozzles require no liquid pressure and can be used with gravity fed liquids or lift liquids from a siphon height as much as 36 inches (91cm). They combine liquid and compressed air to create a mist of atomized liquid that can be easily adjusted to meet the needs of your application. With EXAIR’s siphon fed atomizing nozzles, you can coat, lubricate, cool, treat and paint a variety of products using compressed air and liquids with a viscosity of up to 200 centipoise. » For more information, visit www.exair.com

Epson VT6L All-in-One 6-Axis Robot Wins “Product of the Year” Award at the Assembly Show Epson Robots announced its VT6L All-in-One 6-axis robot won “Product of the Year” award in the Robotics category at the Assembly Show.

Twenty finalists in the “Product of the Year” program displayed their latest cutting-edge technology and equipment. Epson’s VT6L All-in-One 6-Axis robot is a new entry level offering to the award-winning 6-Axis line up. With a reach up to 900 mm and a payload up to 6 kg, this compact, easy to install robot includes next generation technology, is ideal for a wide range of simple applications and is offered at the ultra-low cost of $13,900. » For more information, visit epsonrobotics.com

|

44 IMD JANUARY 2020

GMTA Presents New Profilator Machines GMTA, the North American distributor of Profilator, has added new machines using the process modules it already supplies. Profilator is suitable when customers require complex machining proceses to be carried out effectively, efficiently and with high precision.

Today, an operator working on a modern machine expects a flexible manufacturing process, short cycle times, reduced investment and running costs. With these requirements in mind, Profilator offers polygon & face slot machining, gear tooth pointing, chamfering and deburring, gear and spline cutting, shifter stop machining and Scudding®. Gear cutting is used both for the Profilator rotative gear cutting with inserts and for hobbing. » For more information, visit www.gmtamerica.com

IMD – The Industry’s Most Extensive Industrial Publication

SAFETY IS OUR BUSINESS H.E.

1050°F Cabinet Oven From Grieve

360°

No. 1049 is a 1050°F (566°C), cabinet oven with two drawers from Grieve, currently used for annealing or normalizing processes at the customer’s facility. Workspace dimensions of this oven measure 39” W x 102” D x 51” H, with two drawers rated 250 lbs. loading with 36” wide x 78” deep x 15” high loading area. 800,000 BTU/hour installed in a modulating natural gas burner, while a 10,000 CFM, 7-1/2 HP recirculating blower provides horizontal airflow to the workload.

This Grieve oven features 10” thick insulated walls comprised of 2” 2000°F ceramic blanket and 8” of 10 lb/cf density rockwool.

NEW

» For more information, visit www.grievecorp.com

5:1 Design Factor

Made in USA

200% Proof Load Tested

ASME B30.26 Compliant

Special Configurations Available Upon Request

LEARN MORE

at www.adbhoistrings.com | 800.423.4425 Multitasking QUICK TURN 200MSY from MAZAK The QUICK TURN 200MSY CNC turning center with Multi-Tasking capability brings together advanced technology, productivity and value to deliver exceptional performance for shops large and small. As an (MSY) configuration, this machine offers the greatest versatility available in the QUICK TURN series. The machine features milling capability and Y-axis functionality as well as a second turning spindle to process parts in DONE IN ONE® operations.

Plus, the machine comes with the SmoothG CNC that features MAZATROL conversational programming, complete with monitoring and diagnostics, and EIA-ISO programming as standard. For fully automated operations, the machine can be outfitted with a bar feeder or gantry robot loader.

Follow us on facebook @americandrillbushing 5740 Hunt Road | Valdosta, GA 31606

» For more information, visit www.mazakUSA.com INDUSTRIAL MACHINERY DIGEST.COM ADB Hoist Rings Ad_01 .indd 3

|

IMD 45 8/13/19 11:31 PM

Mention SBSDA2019 for a 10% Discount!

YES… WE HAVE THAT!

DENVER BREAKER & SUPPLY One of the Nation’s Largest Inventory of

NEW, Reconditioned, & Obsolete!

• Circuit Breakers • Panel Mount Switches • Motor Controls • Bus Duct Plugs • Transformers • Starters • and More!

WE SPECIALIZE IN THE TOP BRANDS & CARRY THE HARD-TO-FIND ITEMS Providing Same Day, Next Day Air Shipments for Emergency Needs!

WE ALSO BUY YOUR USED EQUIPMENT…

CALL US TODAY!

855-4UR-BRKR

WWW.DENVERBREAKER.COM All Breakers are Insured and Guaranteed — All Material is Fully Load Tested.

|

46 IMD JANUARY 2020

Stay Connected

Standard-Direct.com CUSTOM or STANDARD call 800-622-2692

INDUSTRIAL MACHINERY DIGEST.COM StandardDirect-Q-09-2018.indd 1

|

IMD 47 8/23/18 2:10 PM

SELECT

EQUIPMENT

Industrial Electrical Sales MCC BUCKETS & MOTOR CONTROL CENTERS CUSTOM BUILT MCC BUCKETS • LARGEST INVENTORY IN THE MIDWEST!

WE CAN RETROFIT ANY MAKE AND MODEL OF MCC BUCKET WITH ALL NEW COMPONENTS INCLUDING VFD’S! SOFT STARTERS NEMA & IEC STARTERS

888-459-5191 • SALES@SELECTEQUIPMENT.NET SELECTEQUIPMENT.NET

|

IMD JANUARY 2020 48SelectEquipment_SBS0917_FP.indd

1

11/21/17 6:22 PM

classifieds

IMD – The Industry’s Most Extensive Industrial Publication

www.enmco.com www.enmco.com

MachineShopWeb.com

OIL MIST & SMOKE IN YOUR SHOP?

...............Visit Online Today!...............

www.mistcollectors.com Tel: 1-800-645-4174

AmericanMachineShop.com LCD Vibration Activated Hour Meter With Service Alerts

...............Visit Online Today!...............

HOURMETER T56E

BoothLocation.com

Need Need Work Work Benches Benches Need Work Benches

HOURMETER T56E

LCD Vibration Activated Hour Meter With Service Alerts

HOURMETER T56E

???

InIn Stock-Factory Stock-Factory Direct In Stock-FactoryDirect Direct

LCD Vibration Activated Hour Meter With Service Alerts

Visit IMD @ IMTS BOOTH 237179

workbenchmarket.com

workbenchmarket.com workbenchmarket.com workbenchmarket.com

MADE IN THE U.S.A

e-mail: customerservice@enmco.com

MADE IN THE U.S.A

e-mail:

TOLL FREE 888-372-0465 customerservice@enmco.com TOLL FREE 888-372-0465

ENM-5-col-092019.indd 1

8/26/19 11:59 AM

MADE IN THE U.S.A e-mail: customerservice@enmco.com

Did You Know?

ProLine-2RClass-112018.indd 1

10/19/18 11:18 AM

Advertisers in our Classifieds section also get exposure in our Bi-Weekley Surplus Buying & Selling Guide? Inquire today how you can increase your exposure with this unique advertising opportunity.

Contact Lisa Hanschu for more information: lisa@indmacdig.com

TOLL FREE 888-372-0465

Welcome to the NEW IMDauctions.com

Auctions Auction Services Machinery Listings

GE NC/CNC Parts & Electronic or Mechanical Field Service

We can RETROFIT your machine!

TROY, MI

FAGOR CONTROL • SERVO DRIVES LINEAR SCALES 248-543-8262

www.DHMassociates.com

Check it out!

IMDAuctions-6th-01-2019.indd 1

DHM-8th-09-2019.indd 1

9/5/19 11:19 AM

12/28/18 7:07 AM

Only $4575

INDUSTRIAL MACHINERY DIGEST.COM IMDauctions-8th-022019.indd 1

1/30/19 8:06 AM

|

IMD 49

Ad INdex Accudyne Products USA — www.ezpullerusa.com ........................................................................29 Actek Manufacturing and Engineering Inc. — www.actekmfg.com ............................................ 37 ADB Hoist Rings — www.americandrillbushing.com ......................................................................45 AmCon — www.amconshows.com .................................................................................................... 41 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ................................. IFC, 19 Attica Hydraulic Exchange — www.ahx1.com .................................................................................. 33

SERVING AMERICAN MANUFACTURERS FOR OVER

33 YEARS

Betenbender Manufacturing, Inc — www.betenbender.com ....................................................... 25 Carell Corporation — www.carellcorp.com ........................................................................................ 5 Cosen Saws, USA — www.cosensaws.com ...................................................................................... 15 Denver Breaker & Supply — www.denverbreaker.com ..................................................................46 Design2Part Shows — www.d2p.com ................................................................................................42 DHM Associates, Inc. — www.dhmassociates.com ........................................................................49 Dynabrade, Inc. — www.dynabrade.com ......................................................................................... BC Eagle Bending Machines — www.eaglebendingmachines.com ..................................................... 5 ENM Co — www.enmco.com ..............................................................................................................49 Essex Structural Steel Co. — www.essexstructuralsteel.com ........................................................ 47 Formdrill USA Inc. — www.formdrill-usa.com ................................................................................. 27 H&K Equipment, Inc. — www.hkequipment.com ............................................................................ 47 HMI div of Betenbender Manufacturing — www.betenbender.com ...........................................43 IMDauctions.com — www.imdauctions.com ...................................................................................49 IMTS | International Manufacturing Technology Show (IMTS) — www.imts.com .................. IBC Kanetec — www.kanetec.com ............................................................................................................. 47 KHK Gears — www.khkgears.us ........................................................................................................... 35

IS YOUR COMPANY LISTED? IMD’s New online Directories. Searchable directories with over 400 categories specifically designed for the industrial machinery industry.

IF YOU’RE NOT LISTED, YOU’RE MISSING OUT!

L&L Special Furnace Co., Inc. — www.llfurnace.com .....................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ...........................42 Micron Group — www.microngroup.com .......................................................................................... 9 Pro-Line — www.1proline.com ............................................................................................................49 Radwell International, Inc. — www.Radwell.com ...............................................................................1 RAS Machine Tool Technologies Inc. — www.rasmachinetool.com ...........................................39 Royal Products — www.mistcollectors.com .....................................................................................49 Schweiss Doors — www.schweissdoors.com ..................................................................................49 Scotchman Industries, Inc. — www.scotchman.com ....................................................................... 3 Select Equipment Company — www.selectequipment.net ..........................................................48 Standard Direct.com — www.Standard-Direct.com ....................................................................... 47 Stor-Loc — www.storloc.com ..........................................................................................................7, 31 Suhner Industrial Products — www.suhner.com ............................................................................. 13 Tormach — www.tormach.com ...........................................................................................................17 Trim-Lok — www.trimlok.com ............................................................................................................. 23 US Shop Tools — www.usshoptools.com ..........................................................................................11

|

50 IMD JANUARY 2020 IMDdirectory-Listed-TV-01-2019.indd 1

3/26/19 8:59 AM

PRSRT STD U.S. POSTAGE PAID BOLINGBROOK, IL PERMIT NO. 467 3590-B Hwy 31 South PMB #233 Pelham, AL 35124

www.INDUSTRIALMACHINERYDIGEST.com

WE LISTEN. WE OBSERVE. WE OPTIMIZE.

WORKSTATION RUNNING

EFFICIENTLY? Dynabrade Cost Savings Evaluation

A cost savings evaluation conducted by a trained Dynabrade Territory Manager is a thorough inspection of an operator’s work environment, application demands, and air tools. Utilizing Dynabrade’s Performance Assurance Kit, our goal is to maximize productivity and performance while increasing efficiency and lowering operating costs at any workstation.

Savings can be realized in many ways, like reducing waste, eliminating steps in a process, or maximizing abrasive value.

Dynabrade Territory Managers are trained to identify areas for improvement, make recommendations and document savings.

Contact Dynabrade to schedule your free, no-obligation Performance Assurance Evaluation today!

PROUDLY DESIGNED, ENGINEERED, AND BUILT IN AMERICA SINCE 1969

dynabrade.com

Dynabrade, Inc. | 8989 Sheridan Drive | Clarence, New York 14031 | 1.800.828.7333