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Manufacturing Showcase: Rollomatic, Inc. IndustrialMachineryDigest.com
March 2021
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Table of Contents
COLUMNS
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BUSINESS 4.0 How Bad Inventory Management Can Impact Your Firm's Organizational Performance By: Kristie Wright
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TALKING SHOP Cate K. Smith, J.D., M.P.A. Executive Director, Precision Machined Products Association (PMPA)
20 FEATURES
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MANUFACTURING SHOWCASE Rollomatic, Inc. By: Russ Willcutt
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WORKFORCE DEVELOPMENT Redeploying Your Skilled Workforce with Automation ActiNav Boosts Competitiveness and Extends Lifespan of Legacy Equipment at PrecisionForm
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NEW TECH
Real-time remote collaborations with SMEs enable effective hardware and software installations
DEPARTMENTS
Addressing Machine Complexity With Intelligent Performance Engineering By: Rahul Garg
30 PROCESS
Total Shop Floor Control with Supply & Demand Global Shop Solutions ERP Software eliminates one custom job shop’s ongoing problems in inventory management, scheduling, purchasing, and accounting
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SAFETY & MAINTENANCE Advancements in Virtual Support
INDUSTRY INSIGHTS How to Choose the Best Drill Type for the Next Job Deciding between solid drills or replaceable insert drills By: Deborah Froelich and Rob Brown
6 EDITORIAL DIRECTIONS 8 INDUSTRY NEWS 36 PRODUCT SHOWCASE 44 SURPLUS BUYING AND SELLING 49 CLASSIFIEDS 50 ADVERTISER INDEX ON THE COVER
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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. Learn more at www.Radwell.com
Editorial Directions SERVING AMERICAN MANUFACTURERS FOR OVER
As many personality types as there are, I think we can all agree the primary distinction is between “extroverted” people as opposed to those who are considered “introverted.” I’ve struggled with this my entire life, being the shy, retiring creature that I am, but one experience with a former employer threw the distinction into sharp relief. It was a smaller publishing company with four trade titles, and the senior editors for these books were familiar to me: we went to college wanting to work with words. We were mostly quiet, thoughtful people with a desire to help shape editorial into a cohesive element that a person would enjoy reading, even if they didn’t quite know why. Then, at some point – and I’m sure it had to do with trimming expenses or maximizing revenue – you began to see more people from other backgrounds entering the editorial field: sales and marketing professionals, newspaper journalists being hired for magazine jobs, bloggers being thought of as writers just because they were a whiz at social media – even though we all know what a toll the internet has taken on grammar and good writing no matter what country you call from. This sets up a perfect “introverts vs. extroverts” scenario. The company I mentioned working for had designers and editors with magazine backgrounds, but the editorial manager came from a newspaper background in sportswriting. We were moving from a comfy old office space with plenty of offices into a new suite based on the “open architecture” style, meaning no privacy, constant distractions and interventions, an air of general suspicion; just a shattering experience for someone used to really delving into a page of copy and giving it the respect your profession demanded. The extroverts were delighted, of course, with meetings devolving into contests and “brainstorming” meeting that reward quick thinking, not absorbing information and processing it thoroughly before delivering a carefully considered response. They lost a lot of excellent employees learning that lesson. I guess all I’m saying here is that it’s always a valuable exercise to appreciate having a team whose members see things differently, and that should be rewarded rather than punished. A great book on this subject is “Quiet: The Power of Introverts in a World That Can’t Stop Talking” by Susan Cain. She has also appeared on TED Talks, which is well worth 15 minutes of anybody’s time.
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Industry News Tormach Names Darcy Johnson Chief Financial Officer Tormach Inc. has announced it has appointed Darcy Johnson as the company’s Chief Financial Officer (CFO). Prior to joining Tormach, Darcy worked with various clients as their Interim Chief Financial Officer, partnering with Lauber Business Partners in Milwaukee. Before that, she worked for over five years as Director of Finance for Dynamic Solutions (DynaTrap), where she led all finance, IT and HR functions. She was the company’s M&A lead during its acquisition by Woodstream Corporation in late 2019, and worked with them to transition the company. Darcy holds an MBA from the Keller Graduate School of Management at DeVry University and a BA in Accounting and Business Administration from Lakeland University. “We are excited to have Darcy joining our team here at Tormach,” said Daniel Rogge, Tormach’s CEO. “She brings a wealth of experience with her to this position and we’re confident she will help us successfully manage our continued growth.”
Siemens Extends Xcelerator Portfolio With Enterprise-Wide Quality Management System Siemens Digital Industries Software announces Teamcenter® Quality software, a new suite of solutions that provide a closed-loop approach for quality management, from design to manufacturing on the shop floor and back again. Teamcenter Quality helps keep product development, quality planning and continuous improvement processes in synchronization to help maximize the value of change management and configuration management capabilities on the Teamcenter collaboration platform. “Given today’s product complexities and time to market agility needs, leading manufacturers include quality management into their collaboration, change management and data backbone, such as Teamcenter represents today,” said Matthew Littlefield, President and Principal Analyst at industrial transformation analyst firm, LNS Research.
WD-40® Brand Partners with Habitat for Humanity to Help Meet Housing Needs Worldwide Having a place to call home means more now than ever —and WD-40 Brand is helping to make that happen for families across the
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globe by donating 50 cents to Habitat for Humanity International for every 12 oz. can of WD-40 Smart Straw® sold at participating Lowe’s Home Improvement stores. Between February 1 and April 30, 2021, WD-40 Brand will donate up to $50,000 to Habitat for Humanity International to assist the global nonprofit housing organization in creating a world where everyone has a decent, safe and affordable place to call home. The effort marks the second year in which WD-40 Brand is supporting Habitat for Humanity. “WD-40 Company values making things better than they are today with its products and through partnerships with organizations like Habitat for Humanity,” said Erin Bala, director of brand management and innovation at WD-40 Company. “Throughout the pandemic, Habitat for Humanity has continued to advocate for housing solutions that will allow more people to gain access to affordable housing and we’re proud to help the organization achieve its goals.”
Universal Robots’ Safety Expert Recognized in ‘20 Exceptional Women in Robotics and Automation’ List by SME The international group of remarkable women on SME’s list published today represent a comprehensive cross section of technologies in robotics and automation. The list was developed by U.S.-based Smart Manufacturing magazine published by SME in consultation with several leaders across the robotics and automation industries. The list highlights the work of Roberta Nelson Shea, who joined Universal Robots (UR) as the company’s Global Technical Compliance Officer (GTCO) in 2016. She has long blazed the trail for women in a traditionally male-dominated industry; Nelson Shea was the first woman to serve on the Board of Directors of Robotic Industries Association (RIA) where she also participates in mentoring diversity efforts to get women more involved and recognized. “From an engineering and management standpoint, women were and continue to be in the minority in the robotics industry. Fortunately, we are starting to see this slowly changing,” she says. “Since joining UR, I see more female engineers in software development, coding and user interface than I saw before.”
BIG KAISER Presents Fifth Annual Donation to NRL Customers of BIG KAISER helped to raise $6,275 to benefit the National Robotics League (NRL) – the fifth annual contribution to the program. The NRL is a manufacturing workforce development program of the NTMA that organizes student teams to design and build remote-controlled robots (Bots) to face-off in a gladiator-style competition. Through the process of Bot building, students gain practical knowledge of Science, Technology, Engineering and Math (STEM) – all essential skills for manufacturing careers.
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“We’re not just fighting a skills gap in our workforce, we have an ‘interest gap’ too. The NRL helps create excitement about manufacturing technology and STEM careers,” says Roger Atkins, president at NTMA. “We appreciate BIG KAISER’s continued support year over year, and of course all of the NTMA members who participate in the program to support the NRL.” “I’m really happy we could make this contribution to NRL despite the really difficult year. We need to be there for these kids and stay engaged in all types of programs to promote manufacturing careers,” said Chris Kaiser, BIG KAISER executive advisor.
Wildeck, Inc. Welcomes Michael Troka as New Vice President of Marketing In his new position, Troka will be responsibility for the planning, development, and execution of all marketing strategies and tactics. Troka and his team will create demand for Wildeck’s products and enhance the brand’s awareness and reputation while serving as the industry subject matter expert for the organization. Troka has a 20-year track record of success in both corporate marketing and advertising agency account
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NuTec Employs Epson Cleanroom SCARA Robots to Automate Medical Syringe Manufacturing, Including a COVID-19 Medical Application The robots are employed at various stations within the machine to provide precise, efficient, and cost-effective automation to the customer’s syringe manufacturing process. The concept phase of the project started in 2018, and the machine was ready for operation in November 2020, enabling the OEM to work with government agencies at a critical time to develop a cost-effective process for manufacturing mass quantities of syringes to use in the fight against COVID-19. "Epson’s high-speed G6-Series SCARA robots with Epson RC+® software enable precision processes with exceptional repeatability assembly pick and place capabilities,” said Brent Martz, director of Sales and Marketing, NuTec Tooling Systems. “The ease of use and application versatility within the Epson RC+ development environment plus an ISO-3 rating and compliance with cleanroom standards makes them ideal for this project and the medical sector in general where speed and precision are vital to the manufacturing process.”
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Business 4.0
How Bad Inventory Management Can Impact Your Firm's Organizational Performance
By: Kristie Wright
B
ad inventory management can cost your company tremendous amounts of time, money and, ultimately, its chances of success. It can heavily impact any business’ organizational performance, leaving it with lackluster profit margins and elevated overhead expenses as a result. No business is exempt from the effects of poor inventory management. Even multinational corporations like Walmart know first-hand just how much a disorganized inventory can cost them. The aforementioned grocery chain giant lost a whopping $3 billion to poor inventory control back in 2013, and suffered regular stock-outs for months after the fact. If this is how improper inventory practices and protocols affect massive corporations, it might be easy for you to imagine how the same mistakes could affect your business. These mistakes have led to many manufacturers closing their doors and have left others struggling amid seas of debt and organizational challenges.
Big Risks for Manufacturing Firms The risk of losing your business is reason enough to accept that bad inventory management is worth avoiding. This sort of fundamental problem with your firm can negatively affect your bottom lines and can even hold your company back from its long-term growth goals. Manufacturing and fabrication firms can be particularly hard-hit too. They rely on a structured inventory of materials and goods to maintain their strict organizational performance.
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Studies have conclusively shown that firms that don’t properly manage their inventories aren’t equipped to avoid the costs of evolving production rates, overtime, unnecessary costs of sales, sub-contracting, and back-order penalties during times of high demand. This can lead to problems with cash flow and slim profit margins, as well as organizational challenges like a lack of alignment, accountability, and trust in managerial staff.
The Signs of Substandard Inventory Management There are dozens of telltale signs to look for that indicate bad inventory management within your business. These signs will vary from industry to industry, but there are several parallels between them. Obvious signs of poor inventory control include: » Frequent stock-outs » Consistently high inventory costs » Low or decreasing inventory turnover rates » Large amounts of obsolete inventory » High working capital rates » Excessive material and product storage costs » Errors in data entry for spreadsheets » Shipping incorrect items to customers and clients » A consistent loss of customers » Imbalanced lead times
There are a number of convergent factors that come together to produce these deleterious symptoms. However, most if not all of them connect to the way you manage your business’ inventory. This means that with a few strategic adjustments, you can remedy these issues and get your manufacturing firm back on the path to success.
The Causes of Bad Inventory Management There could ultimately be hundreds of different reasons why your inventory is being mismanaged. These are some of the most common and probable reasons why your inventory control and the company’s organizational performance is suffering.
1. Spreadsheets Most small to medium-sized businesses (SMBs) use Microsoft Excel spreadsheets to manage their inventory. Spreadsheets tend to start out working well for smaller businesses, but their use can quickly lead to the development of devastating issues. This is particularly true for businesses that are growing rapidly. Stephen Powell of Tuck Business School at Dartmouth College conducted a study of errors in 25 sample spreadsheets to demonstrate this point. He found that 15 of the spreadsheets contained errors. The total number of errors clocked in at a concerning 117. Around 40 percent of those errors discovered had minimal impacts on the businesses studied. However, according to the researchers, 7 of them led to significant losses of between $4 million and $110 million in revenues.
2. Manual Stocktaking and Inventory Tracking Manual inventory tracking and stocktaking are perfectly functional for smaller businesses, but can become time-consuming and prone to errors as your company expands. If you use these processes to manage a medium or large business’ inventory, you’ll always fall one step behind your true inventory levels. This will cause ongoing issues with ordering. Say, for example, your assistant manager skips an essential step in the stocktaking process and fails to update the stock levels. Because of the error, you will likely order too much or too little, and end up with obsolete stock (or stock-outs) on your hands.
3. Large Inventories Hefty inventory volumes can create more managerial challenges, but they can also negatively impact your profits. A large percentage of businesses have between 20 percent and 40 percent of their working capital tied to their inventories. It may be difficult to reduce your firm’s inventory, but it’s important to do so if you want to improve your inventory management and overall organizational performance.
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4. Substandard Forecasting There are two scenarios that can stem from your business not having access to accurate reports regarding customer habits, best-selling products, sales trends, and other vital data. One, you may order too many raw materials and deal with the issues of an overstocked inventory. Two, you could under-order and experience stock-outs as a result. The latter scenario could lose you precious customers. Once you insist on gathering and working with accurate reports, you’ll be able to better predict your customers’ future behaviors. This means you can order raw materials to manufacture products that meet customers’ demands without exceeding your firm’s budget. Accurate forecasting not only helps you stay within your budget, it can also determine whether you’ll need additional funding to facilitate growth. This is where a tool like a business loan calculator can come in handy, as it assists in determining the true costs of a loan. Using this data, you can ascertain how feasible your growth strategy is, and by how much you can afford to scale up your inventory.
Solutions for Bad Inventory Management There are a myriad of possible causes for poor inventory management, and you may already have a clear idea of why your business is struggling. That said, let’s move on to workable solutions. The first solution you can implement for your inventory woes is to read up on the best inventory management practices. You can more effectively manage your inventory and warehouse, and train your staff to do the same once you have the knowledge and skills needed for the job. Second, you can investigate implementing a cloud-based inventory management program. Reliable programs offer tools and metrics like: » Accurate and up-to-date forecasting » Automated data entry » Real-time inventory tracking All of these can help you develop a more effective strategy for managing your manufacturing business’ inventory. Cloud-based inventory management has the power to improve your firm’s customer service and stock visibility. At the same time, it offers convenient and automated inventory updates that can make your management chores simpler. Cloud solutions offer superior safety and security, as all of your inventory data is encrypted and stored on secure virtual servers. Plus, they boast real-time operational visibility of order execution, selling processes, and dispatch of goods to enhance your organizational capacities.
Streamlining Inventory Management for Success Bad inventory management can eat away at your company’s profits and organizational structure while driving up operational costs. Consider implementing cloud-based inventory management software and researching best management practices. This will give your company an organizational performance boost.
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Cate K. Smith, J.D., M.P.A. — Executive Director, Precision Machined Products Association (PMPA) Could you discuss the academic and professional journeys that brought you to your present position? Both my dad and my maternal grandpap worked in manufacturing, but my family were part of a generation that wanted their kinds to “do better,” which meant going to college. I enrolled at Bowling Green State University and earned a degree in sport management, working summers at a nearby steel mill shoveling oil, cleaning electrical panels, and degreasing machinery. I then went Cleveland State University to obtain my Juris Doctorate. Professionally, I worked my way up from law clerk to associate attorney, and that’s when I made my transition into association management as Executive Director of the Delta Theta Law Fraternity, where I spent 11 years before holding that same position at the Education Law Association for the next 10 years, during which I earned a Master’s in Public Administration. I heard about the PMPA opening through my network in the Ohio Society of Association Executives, and it just looked like the perfect fit for us both. So that began the most thorough interview process of my life – all of my previous positions had basically come
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about through networking – since the PMPA wanted to feel assured that we were making the right decision. For me, at least, that’s definitely proven to be true; especially when I found a pencil in my desk drawer bearing the logo of the vocation school where my husband works my first day on the job. I took that as a sign this was meant to be.
In what ways has your legal training been useful in your position with the PMPA over the past year and some months? In terms of my legal training, I think learning to think critically and develop logical thought processes is a definite benefit in this position. The communication skills a lawyer must acquire to be able to ask questions without appearing accusatory is equally important for a leader. In addition, I’ve been able to examine and understand the legal issues we encounter. As for my professional experience, working for small associations has trained me to keep an eagle eye on the budget, so everyone on the PMPA team has already learned that my first question about a project, whether it involves marketing, events, or new member benefits, will
always be “what will it cost?” If you keep your bottom line solid by being a good steward of membership dues and staying member-focused, then you’ve got a firm foundation to stand on.
How has the PMPA helped its members weather the recession and pandemic, and how will you continue doing so once recovery begins? As a case in point, we knew our members were essential industries even before the government did, because we started receiving RFQs for large numbers of ventilator parts requiring fast-track delivery times. We knew that our members were busy handling plenty of issues on their own, so we became the clearing house for authoritative information – about the virus, about the public health measures, and about the legislative steps being taken to help them keep their performers employed. We’ve tailored our support for members by rethinking what type of information should be appearing online, and in what form. For instance, with the new administration in place we expect to offer guidance for the many anticipated regulatory changes headed our way. We’ve
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also increased our online resources by establishing platforms like the Tech Tuesday Webinar Series, which can be accessed on our website, and launching a Podcast Series that’s now at more than 52 episodes and 3,400 downloads. In addition, we are currently building a searchable online library to bring a wide variety of technical information to our members’ fingertips. And of course, that is on top of the work we do every day to help them solve operational and technical problems, understand business, quality, and regulatory requirements, and to otherwise do whatever it takes to help them adapt and thrive.
What has impressed you most during your time with the PMPA? I continue to be amazed by how “member-centric” this association is. Everything we do is focused on the benefit it provides to our membership, and they are involved in our decision-making process to a degree Miles Free and Cate Smith traveling to meet with PMPA members in pre-pandemic days. that’s really encouraging to see. As for the industry at families, discovered that we are all better together. And that the large, it’s wonderful to see how manufacturing, and world really needs what it is our talented people make. Essential of course precision machining specifically, has evolved into this manufacturing, yes. We support it every day. Our members’ parts sophisticated, super-clean environment since my dad and granpap’s make a difference in everyone’s lives. time. We’re proud that we delivered, so they could deliver. When the world desperately needed what we had to deliver. With PMPA, all of our member companies, their employees, and those employee’s Learn more, and consider joining, by going to pmpa.org.
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Safety & Maintenance
Advancements in Virtual Support Real-time remote collaborations with SMEs enable effective hardware and software installations
T
he impact of COVID-19 on manufacturing facilities has been significant. While offices across America have largely pivoted to online platforms for web-based collaborations between colleagues, the industrial sector has also had to contend with how to safely startup and commission process control systems in their facilities which have traditionally required timely on-site interventions and communications with product experts. Commissioning a process control system requires extensive collaborations between an on-site field team and their vendors whose engineering support teams have been largely working remotely. The challenge for vendors has been how to continue to support their customers with effective training and mentoring. According to ARC industry reports, human error is the primary cause of 42 percent of abnormal events and a secondary contributing cause in over 65 percent of the cases, so there can be no training or support shortcuts.
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Advances in both hardware and software tools enable remote mentoring to be possible where expert knowledge can be delivered to reduce risks and ensure effective startups. This now includes intelligent wearable devices that enable remote experts to see what a field technician sees when working on hardware in a facility. With such advancements, it is now possible for a single remote expert to assist multiple people and facilities at the same time without travel. Accelerated by the working constraints caused by the pandemic, the adoption of these technologies is now suggesting a bigger role for remote-based training and support of manufacturing and process control system needs after the pandemic is over. One company that has embraced the capabilities of remote support even before the pandemic is Quakertown, Pennsylvaniabased NovaTech Automation - a leading provider of procedural automation solutions for the past 30 years whose patented software is used in high-risk government applications.
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“Long before COVID-19, we were applying advances in web technologies that would allow us to deliver cost and mission effective remote support services to our customers,” said Dwight Wood, Vice-President, Global Sales, NovaTech. “Today we are just doing it at a different level - whether it is to troubleshoot issues, support a remote startup or collaborate on a commissioning.”
The Role For Virtualization And Simulation Before COVID-19, implementing a new process control system would typically entail bringing the experts who developed the application software into a facility to work with plant engineers on design, factory acceptance testing and startup and commissioning. “Customers want the person who actually developed the code supporting them as directly as possible,” said Wood. “With our virtualization and simulation technologies, a customer can now effectively startup a facility and still have the subject matter expertise on hand in real-time to walk them through the process,” said Wood. “We will also have already checked out the system together remotely through a factory acceptance test.” These remote collaborations can significantly reduce the time spent in the field with a customer in locations where it is still permitted. Wood estimates that on-site time is now reduced by half and up to two-thirds. And when lockdown requirements do not permit a visitor coming on-site, remote support is proving to be an effective replacement.
Commissioning projects will often involve both software and hardware component with hardware-focused implementations usually containing some level of software support as well.
Hardware Commissions NovaTech Automation integrates an intelligent wearable solution for customers when a commissioning effort involves hardware so that their support teams can see exactly what the technician is viewing such as when wiring an I/O cabinet or installing a new controller. The company uses a RealWear HMT-1 headset technology that is a ruggedized Android computer that an operator wears on their head. Instead of using a traditional touch screen, it provides an articulated micro-display that gives the appearance of a 7-inch tablet screen. The headset is entirely hands-free and utilizes a voice-based operating system with local speech recognition. Multiple digital microphones enable use in loud areas. It is designed to be worn with standard hard hats, bump caps and safety glasses and is for use in explosive areas, combustible zones and hazardous environments. NovaTech uses the headset to provide remote support through established collaboration platforms such as Microsoft Teams or Cisco WebEx. “We have the ability to have our eyes and ears available to the technician in the plant and assist them in a prudent, real-time manner, so that they can install that piece of hardware and do the wiring correctly,” said Wood.
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In 2020, one of NovaTech’s customers was upgrading their D/3 distributed control system and needed prompt engineering support to ensure a smooth transition to their new version. The customer had a RealWear headset with Microsoft Teams installed. After initiating a video call with a NovaTech support engineer, the customer was able to share their camera and the support engineer walked him through the entire upgrade process.
Software Installations Remote support for software installations must be done with cybersecurity in mind requiring multi-factor authentications. “Our support teams are able to go into the software securely and pull up the same data and screens that a plant engineer sees, so they can assist them through the startup of a new piece of application software or a software upgrade,” said Wood. “Some of our customers consider what we have been able to accomplish together as a paradigm shift in remote support services,” said Wood. “So, as we move out of COVID, we expect more customers will want to move in this direction. Besides lowering the infection risk, there are fewer safety risks overall when you reduce the number of people physically working in a facility. Travel time and costs associated with sending people to a plant are also reduced.”
Reimagining Workflows from Startup To SOP Just as the pandemic required operators and vendors to quickly pivot to new remote-based workflows for startups and commissioning, digital solutions are now available to support SOPs for the maintenance and ongoing support of the updated equipment and software through augmented manual procedure (AMP) software. AMP software enables facilities to replace their paper-based SOPs with a digital format that is capable of operating on a wide range of hardware such as smartphones, PCS and tablets.
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In the field, manual procedures are linked via the operator’s mobile or stationary device interface to the process control platform through software that enables bidirectional communication regarding equipment status and task completion. Information is displayed as an operator-friendly checklist with completed tasks self-audited and timestamped for future reference and compliance reporting. It is therefore ideal for distributed teams working remotely. AMP software developed by NovaTech ensures accurate SOP execution along with validation of manual tasks and comprehensive information capture/sharing. The company views AMP as another example of how technology can better support field work. According to NovaTech’s Wood, “Just as we now train and mentor on best practices remotely, afterwards facilities can establish or update their SOPs digitally and integrate them with their existing control system. SOP’s are then much easier to update, streamline and standardize across the organization in the future.”
A New Era of Remote Support Whether supporting software or hardware-based projects, expert mentors are increasingly working with operators and technicians remotely to execute upgrades, startups and commissions, complete complex tasks and support training and continuous improvement programs. “As a partner to our customers, what really excites us about the coming together of these technologies is the ability to provide cost and mission effective real-time support,” said Wood. “We can literally have a window on their work with the capability to answer questions, optimize installations, troubleshoot issues, and receive feedback from our customers. This way of working together is highly complementary to being together in-person and we expect that it will be here to stay in some form well beyond the pandemic.” For more information, visit the NovaTech website at www.novatechautomation.com/amp or call 1-844-668-2832.
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Manufacturing Showcase
Rollomatic, Inc. By: Russ Willcutt
T
he years seem to fly by as you consider the company’s founding in 1964 in Switzerland to the global OEM it is now less than 60 years later. Launched by Francis Rollier as a cutting tool manufacturing firm for the local watch industry, it wasn’t long before new advents began to accumulate: the first manual flute and relief grinder called “Roll-o-Matic” for in-house use; the first CNC grinder for pointing with a patented positioning system; the first cylindrical grinder with simultaneous roughing and finishing operations (patented); and the first CNC fully-automatic 6-axis grinding center, the CNC600X. The company’s strategic plan for growth – beginning by targeting Europe and the Far East – led to its first U.S footprint in the Chicago area in 1993. While it had serviced the N.A. market through representatives and distributors for quite a few years, the idea was to grow closer to its end-users while at the same time strengthening and streamlining its global structure. Once the headquarters for North American operations had been established in Mundelein, Illinois, an effective distribution network began being developed. With all manufacturing of the company’s products taking place in Switzerland, any necessary customization generally occurs there, with inventory in the warehouse at the Illinois facility either ready to ship or easily tailored to spec. Although satellite locations around the world can conduct grinding tests, cycle time tests, and customer runoffs, etc., all R&D takes place in Switzerland, with weekly teleconferences between sales managers and engineers to share customer feedback and discuss modifications that might be incorporated into future machine tool designs. One result? The GrindSmart 830XW, which utilizes a combination of hydrostatic technology and linear motors to produce large and small series
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with 6 axes interpolated simultaneously; the only machine tool to incorporate these specific technologies together. According to Eric Schwarzenbach, president of Rollomatic’s North American operations, the company’s roots in precision machining remain within its DNA, although it has substantially increased the size, function, and capabilities of its product line (see sidebar). “Although we’re a machine tool OEM now, manufacturing grinders and robotics, we’re still strive toward precision in all our efforts just as we did when our sole focus was on Swiss watchmakers.” The past year has presented Rollomatic with the same challenges it has to everyone involved in industrial manufacturing: when
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your annual outreach depends heavily on attending 8-10 tradeshows around the world, how do you compensate when that option has been suspended? “We responded by creating the Digital Rollomatic World, which can be accessed on our website,” Schwarzenbach says. “It is packed with useful information that’s constantly updated, and even provides a way to schedule one-on-one conversations with our specialists who can help customers address the specific challenges they encounter. We’ve also fine-tuned our webinar content to reflect the changing times. “The most amazing thing, however,” he says, “is that last year we signed up our largest number of new accounts in the company’s history. So I definitely think we’ll have much to learn from this period that will be of permanent benefit once these storm clouds have passed.” Asked whether the global manufacturing industry will emerge from this period stronger for the lessons it learned, Schwarzenbach believes that will definitely be the case, but it also depends on the approach companies chose to take from the start. “You would see the typical reaction, which was start sending people home, but we chose to start training them instead. And that’s already paying huge dividends, which we expect to be magnified once the recovery really begins to gain traction. We didn’t sacrifice our base of experienced employees, so we’re poised to take care of any and all opportunities that come our way.”
The Rollomatic Lineup This is a rough grouping of the company’s product offerings: » Cutting Tool Grinding » Cylindrical Grinding » Software » Peripherals » Humanoid Robotics » Laser Machining
Learn more about these products and more at www.rollomaticusa.com.
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Workforce Development
Alex Corckran, (right) President and CEO at Precision Form with Justin Griffin, Channel Development Manager at Universal Robots, watch the ActiNav teach pendant run through the actions the system performs. “This initial task for ActiNav was actually a very simple choice,” says Corckran. “Our CNC machine cuts scallops in a part for firearms. it’s a minute and a half cycle time, and it takes one operator to sit there the whole time and tend the machine. Deploying ActiNav for this task instead has worked incredibly well.”
Redeploying Your Skilled Workforce with Automation
ActiNav Boosts Competitiveness and Extends Lifespan of Legacy Equipment at PrecisionForm
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recisionForm, a market leader in small custom metal parts, was challenged to automate the task of picking parts in deep bins and inserting them into a CNC machine. The company deployed Universal Robots’ ActiNav system for flexible machine loading, enabling them to boost competitiveness, overcome labor challenges, empower their workforce and extend the lifespan of older equipment. What’s the biggest headache in automating a task? How to present the part to the robot. This was the conclusion PrecisionForm quickly reached when automating their initial project; deploying a robot to pick piston rings and place them on a micrometer for inspection. Like many parts at the Pennsylvania-based contract manufacturer, the rings were batch processed and arrived in big bins,
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all jumbled together. In order for the cobot to pick them, an operator had to lay them out in a grid pattern on a tray first. “50-75 percent of our time spent getting that application up and running was figuring out how the robot would pick the parts,” says Alex Corckran, president and CEO of PrecisionForm. “Having an operator lay out parts for the cobot was still faster than doing the whole inspection process manually, but wouldn’t it be nice if the cobot could just pick directly from the bin and bypass this whole step?” PrecisionForm started researching bin picking solutions for the next project, picking parts out of bins for CNC milling. The company contacted a number of vendors and sent sample parts to determine if they could be picked out of bins. “The answers were always, ‘Yes:
IMD – The Industry’s Most Extensive Industrial Publication
but...’ and the “buts” were never acceptable to us,” says Corckran, recalling how some systems had trouble with parts that were certain colors, others had issues with flat parts, while some systems required the vendor’s engineer to come out and handle the changeover from one part to the next. “We have 50 to 100 parts that we touch on a weekly basis for inspection or secondary processes,” says the PrecisionForm CEO. “The vast majority of those parts are not high enough quantities to justify having a fully automated solution that we can’t easily switch between parts.” Using a bowl feeder for part presentation wasn’t an option either, explains Corckran. “Bowl feeders are effective when you have very high volumes and you have the right part for the job. For other parts, when you have lower volumes, the changeover between one part to the next on a bowl feeder is either impossible, or just takes too long to make it effective. In many cases, it’s just easier to have a person do that work rather than switch over the automation process.”
“I can’t be competitive at an international level in Lititz, Pennsylvania with one operator running one machine at a time,” says Alex Corckran, President and CEO of PrecisionForm. Following the ActiNav deployment, operators can run three or four machines at a time, enabling the company to stay competitive: “This solution allows us to have highly-trained people operating three or four robots, enabling us to use those people in other applications where they’re adding more value.”
Enter ActiNav When Universal Robots (UR) and UR distributor Applied Controls reached out to PrecisionForm to suggest a test of the ActiNav solution, Corckran was skeptical: “We figured it was going to be the same as all the other bin-picking solutions, where we send them a part and weeks later they send us a ‘But.’” Nevertheless, PrecisionForm sent the ActiNav team sample parts along with CAD drawings and 3D models. “We were actually shocked,” says Corckran. “We sent them two parts, including one with a very small, flat surface that never sits in the bin properly and within 24 hours they had sent us three demo videos of ActiNav actually picking the parts out of a bin.” A UR cobot, when combined with an award-winning ActiNav Machine Loading kit creates a flexible and easy to use machine loading solution. The kit consists of hardware and software that integrate seamlessly with the cobot to synchronously handle vision processing, collision-free motion planning, and autonomous real-time robot control.
Simple Automation Choice PrecisionForm already owned a UR3 and a UR5 cobot from Universal Robots; the UR3 handles the initial piston ring inspection process and the UR5 loads and unloads parts in a brake press. Building on its positive experiences with Universal Robots’ cobots and the impressive results of the initial bin picking samples, PrecisionForm decided to purchase an additional UR5 fitted with the ActiNav solution and deploy it for a very simple, low-hanging fruit task;
picking firearm parts out of a bin and loading them into a CNC machine. The task has a cycle time of 90 seconds and requires one full-time operator to tend it, making it a perfect task to automate. The ActiNav system took maybe a day to set up and deploy, says Dan Vazquez, industrial automation engineer at PrecisionForm: “The first step is to define the environment and calibrate the sensors, which is very straightforward. You drag the robot arm to points where you want to place environment objects and once you define those points, the robot will autonomously plan its paths based on that information.” Next, Vazquez simply fed the cobot a CAD file of the part to be picked. “ActiNav will be able to identify the part within the bin, as well as its position on the end effector while it also autonomously plans further movements,” he explains, adding that PrecisionForm implemented two re-grip stations in the cycle where parts are placed to optimize cycle time and give the cobot the correct angle to pick the part for final placement.
The Solution First ActiNav scans the bin. Once it has identified pickable parts that the UR5 can reach and safely move to a re-grip station, the robot picks the part, verifies that it has picked the part, and moves to the re-grip station. Then the UR5 removes the finished part from inside the CNC lathe, places it on second re-grip station, and moves to the first regrip station to insert the blank part into the lathe. While that part is being milled, ActiNav returns to the second re-grip station to place the finished part into a palletized pattern in a box. “The whole cycle time— a minute and a half to two and a half minutes—it’s extremely efficient for us to have a robot doing that,” says Corckran. INDUSTRIAL MACHINERY DIGEST.COM
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About ActiNav Universal Robots' award-winning ActiNav is a flexible, easy to use, machine loading solution that synchronously handles vision processing, collision-free motion planning, bin-picking and autonomous real-time robot control. ActiNav is part of Universal Robots UR+ Application Kit portfolio that decreases project risk and complexity. The kits contain software and hardware components for the most popular cobot applications and are certified to work seamlessly with UR cobots.
The kit consists of: » Autonomous Motion Module » 3D Sensor (placed above bin) » ActiNav User Interface » Alignment Marker » All cables, screws, and brackets » Universal Robots e-Series cobot (UR5e or UR10e)
Learn more at: www.universal-robots.com/actinav
Actinav Empowers Workers, Solves Labor Challenges PrecisionForm can’t be competitive at an international level from Lititz, Pennsylvania with one operator running one machine at a time, says Corckran: “We have a whole lot of very skilled workers. A lot of these very repetitive tasks are intermittent, so we often find ourselves having to take a highly-skilled person and put them on a very repetitive task, and that’s not great for morale, and it’s not cost-effective either.” Following the ActiNav deployment, operators can run three or four machines at a time, enabling the company to stay competitive: “This solution enables us to have highly-trained people operating three or four robots, allowing us to use those people in other applications where they’re adding more value.” In Corckran’s experience, when temporary labor is required to take on intermittent tasks, finding “good, qualified folks to show up on a regular basis when you need them” is a challenge. ActiNav solves that problem: “The robot stays there and doesn’t take a break and it works second shift, third shift, and we can count on it being there the next day.”
UR+ Certified Robotiq Gripper
causes issues with wear and tangling. The Hand-E connects directly to the cobot’s tool input, so there’s no cables to be tangled.”
Inspection With Actinav Gives Legacy Equipment Another 10 Years On The Floor PrecisionForm’s manufacturing facility combines the “latest-andgreatest CNC equipment” with “30-year old equipment that’s still very effective at its job,” says Corckran. The ability to implement ActiNav on older equipment doesn’t just have the obvious ROI of replacing an operator or allowing a single operator to operate four machines, explains Corckran, it allows companies to rethink whether or not that piece of equipment needs to be replaced. “For example, we have some machines that produce very high-volume parts, in the millions a year. At some point, those machines wear out, and they stop producing 100 percent, or 99.999 percent good parts. In the old reality, we would have to replace that machine to stay competitive,” he says. “However, if we can implement ActiNav next to that machine and inspect out the one percent of bad parts, we’ve just taken a million dollar piece of equipment, added a very inexpensive solution to it, and potentially gotten another ten years out of it.” The tolerances of parts manufactured at PrecisionForm are very tight with customers scrutinizing every part. In order to keep the company’s old equipment producing at the level customers
Initially, PrecisionForm had difficulties picking the part out of the CNC lathe because the part was covered in cutting fluid and placed inside very tight quarters. The company equipped the UR5 cobot arm with the Hand-E gripper from Robotiq. Hand-E is a UR+ certified gripper which means it seamlessly integrates with the UR cobot. “The ability of the Robotiq gripper to adapt to new fingers that we designed made it possible to reach in there and pull the part out accurately,” says Vazquez. The gripper is controlled directly through the cobot’s teach pendant. “This is great because you end up being able to have very minute control over the grippers’ movements, as well as the force applied,” explains the industrial automation engineer. “The robot can also use this force feedback to tell whether or not it has picked the part up, or if it may have dropped it. For other applications where we’ve used pneumatic grippers, we typically need ActiNav’s 3D sensor above the bin scans the parts to be picked and sends a 3D point cloud image to the to run air lines along the outside of the robot, which system’s Autonomous Motion Module where the pick coordinates and path are calculated.
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expect, the operators stop once an hour for ten to fifteen minutes and do a full inspection of both the part and the die. “That’s as much as 15 to 20 percent of daily production lost, that we can now recuperate using ActiNav” concludes Corckran, adding that in future application scenarios, PrecisionForm envisages also using an additional ActiNav system on its first piston ring inspection application, eliminating the manually-loaded trays.
ABOUT PRECISIONFORM:
Significant Market Need
For more information, visit www.precisionform.com
Any type of unoriented presentation process is a perfect fit for ActiNav says Chuck Mulcrone, Vice President of Sales with Applied Controls, that distributes Universal Robots in the Mid-Atlantic region. “Historically, in the 3D bin-picking, batch processing market, the cost of entry is prohibitive for most small companies. ActiNav is a game-changer addressing a significant market need in automating high-mix, low-volume production with unstructured parts to be picked,” he says. “It’s a relatively low-cost, low-engineering product and it goes across every industry; from automotive to food and beverage to material handling.”
Originally a division of Alcoa Inc., PrecisionForm Inc. is a contract metal component manufacturer based in Lititz, Pennsylvania. In the more than 32 years since its founding, PrecisionForm has become a leader in custom small parts manufacturing for the automotive, electrical, electronics, aerospace and building sectors. PrecisionForm utilizes both multi-die progressive cold forming and machining techniques, while rotary transfer machines, CNC lathes and machining centers provide automatic station-to-station indexing for accurate secondary operations, enabling the company to minimize raw material cost and eliminate waste.
ABOUT UNIVERSAL ROBOTS: Universal Robots (UR) was founded in 2005 to make robot technology accessible to all by developing small, user-friendly, reasonably priced, flexible collaborative robots (cobots) that are safe to work side by side with people. Since the first cobot was launched in 2008, the company has experienced considerable growth with the user-friendly cobot now sold worldwide. The company, which is a part of Teradyne Inc., is headquartered in Odense, Denmark, and has regional offices in the United States, Germany, France, Spain, Italy, UK, Czech Republic, Poland, Hungary, Romania, Russia, Turkey, China, India, Singapore, Japan, South Korea, Taiwan and Mexico. In 2019, Universal Robots had a revenue of USD 248 million. For more information, visit www.universal-robots.com
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New Technology
Addressing Machine Complexity with Intelligent Performance Engineering By: Rahul Garg
O
ne of the principal challenges for machine builders is trying to contend with and respond to demands for increased machine customization, and the associated increase in complexity that comes when trying to fulfill those requirements. Intelligent Performance Engineering (IPE) helps solve these challenges for companies that are developing new engineering practices that keep pace with the growing sophistication associated with machine introductions.
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Implementing Digitalization Technologies Technology is the most significant catalyst for change and staying competitive in an Industry 4.0 landscape with new machine introduction. However, several other factors drive companies to shift, including meeting customer demand for machine personalization through specifications and requirements. Therefore, a machine must meet, exceed, and support the performance requirements of the daily increasing explicit use cases.
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Given these factors, it is crucial to differentiate a product from global competition by serving customers rapidly at a lower cost. Though these objectives are a mainstay, dynamic technologies propel companies to consider and evaluate how they meet customer’s needs and challenges while using digitalization. Therefore, in stretching the limits of the technology advancements, there is an ongoing need to address the growing demands of flexibility and complexity. You cannot accomplish this objective without quickly evaluating machine behaviors and providing data back to the model. Intelligent Performance Engineering provides the ability to ensure innovative machine designs can be delivered as promised through a digital thread to support consistency and high performance. This innovation provides several critical design parameters, including personalization, global competition, and simulation, while adopting intelligent performance engineering practices for ensuring safety, reliability, and cost-effectiveness. Implementing IPE in conjunction with a digital thread is vital to balancing a customer’s needs to improve machine reliability and performance while evaluating, verifying, and testing designs.
Simulation Measures Performance As corporations deliver machines with faster cycle rates, higher reliability and constricted delivery schedules, simulation is performed upfront versus conventional testing of multiple physical prototypes. With this shift, IPE simulation and testing can collaborate proficiently to address the essential needs of modern machines. One of the most critical aspects of designing new industrial equipment or modifying existing designs lies in verifying and testing to analyze its performance before reaching the customer. Consequently, original equipment manufacturers (OEMs) can adopt a collection of digital simulation and analysis tools to understand the design choices that affect performance and failure for a component, device, or machine. It costs much less to address the design process’ problems rather than trying to address potential issues with your machine design in the product development cycle. In conventional methods, there still exists some manual handoffs between design and simulation processes. Engineers can use design level simulation that provides a baseline assessment of the design or a definitive design analysis leading to more advanced simulation. As enterprises attempt to deliver machines with faster cycle rates, and compressed delivery schedules, teams are under pressure to perform simulation early rather than testing several physical prototypes, assuming these physical tests will suffice. Therefore, the objective is to have simulation and testing working together efficiently.
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Analyzing and Integrating Machine Data There is some manual work involved in running simulations to verify various equipment characteristics using multiple tools. As a result, basic simulations do not consistently reflect the interdependency of issues like electromagnetic interference, structural loads, heat, and vibration. This scenario is becoming an issue with smarter equipment, increasing the complexity of wiring, electronics, and software. The designer may run a fundamental analysis to validate design safety but hinder the designer from exploring the performance ramifications of engineering trade-offs. Also, a designer may over-engineer a design, thus bypassing the need to run as many tests. However, this may lead to additional cost, weight, or reduce machine performance to meet safety requirements. Therefore, the analyst may adopt complex processes to address simulation tool intricacies and lack of design tool integration. And, any delays in the process may result in performing risky analysis on outdated designs. The digitalization process, including the digital twin, requires optimum integration levels – an essential for OEMs. A comprehensive digital twin improves the simulation of various characteristics of components and equipment more precisely, enabling faster delivery of a more reliable and smarter machine. A digital thread also automates the information sharing process between engineering teams, analyst production, test team, and service engineers. This progression allows teams to evaluate capabilities and limit product variations efficiently. Better integration between designers, analysts, and live data enables OEMs to adopt intelligent performance engineering practices to improve engineering speed and deliver higher performance while ensuring safety, reliability, and cost-effectiveness. Intelligent Performance Engineering improves reliability and addresses risk by building a set of highly accurate models to predict product behavior during lifecycle phases. What makes it a unique approach in the marketplace today is understanding industrial machine and equipment manufacturer’s process needs and challenges. The resultative data on those issues identify three crucial areas:
» Multi-physics simulation gives customers the ability to balance multiple attributes under one umbrella. For example, deciphering thermal and stress analysis in combination. So, what happens when the heat rises? And what is its impact on product stability? There are multi-physics simulation angles implemented together to address several needs that are normally isolated. Having the ability to balance the performance characteristics across the physics domains becomes valuable. » Integrated design and simulation focus on performance engineering to address the front-end product design commissioning process that ensures models are consistent with high variability – managing many changes while not losing data while keeping all in sync. » Closed-loop validation expands the test horizon to look at the testbed, or machine prototype, or machine in operation, as the testing environment. Subsequently, you receive more information from machine use by getting real-time feedback from it as part of the test analysis.
Siemens Digital Industries Software drives the transformation to enable a digital enterprise where engineering, manufacturing, and electronics design meet tomorrow with the Xcelerator portfolio. Xcelerator is a comprehensive, integrated portfolio of software, services and an application development platform, which accelerates the transformation of businesses into digital enterprises. It unlocks a powerful industrial network effect – essential requirements to leverage complexity as a competitive advantage, no matter the industry or company, to transition seamlessly to create tomorrow’s complex, efficient machines.
ABOUT THE AUTHOR: Rahul Garg is vice president for the industrial machinery and mid-market program at Siemens Digital Industries Software, responsible for global business development. He and his team deliver strategic initiatives and develop solutions,
Balance Between Productivity, Accuracy, Reliability, And Efficiency
working with industry-leading customers
As industrial equipment becomes more complex with faster delivery expectations, leading industrial OEMs must build more effective and trustworthy simulations. Developing industrial machinery requires finding the best balance between productivity, accuracy, reliability, and efficiency – performing it digitally to out-innovate the competition.
machinery industry. Rahul’s 25-year career includes delivering
to provide thought leadership on new, emerging issues in the software-based solutions for product engineering and manufacturing innovation globally. He has held leadership positions in research and development, program management, sales and P&L management, focusing on industrial machinery and heavy equipment since 2007.
CUT IT ON A COSEN | www.cosensaws.com INDUSTRIAL MACHINERY DIGEST.COM
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Process
Fully automated machining center, the blanks go on one belt and the finish parts come out on the other.
Total Shop Floor Control with Supply & Demand Global Shop Solutions ERP Software eliminates one custom job shop’s ongoing problems in inventory management, scheduling, purchasing, and accounting.
T
MCO, Inc. is a custom job shop that has specialized in one-stop, concept-to-completion metal manufacturing services since 1974. With a wide range of metal fabrication services that includes machining, sheet metal and tube fabrication, water jet cutting, welding, powder coating, and assembly, TMCO can finish a product from any stage of the design, fabrication, paint, or assembly process. Headquartered in Lincoln, Nebraska, TMCO is ISO 9001:2008 certified. In addition to its custom fabrication services, TMCO also operates three subsidiaries that produce a diverse array of make-to-stock
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metal products. These include Metal + Art, a full service design and fabrication studio serving the architectural industry; National Manufacturing, which makes ovens, mixers and other equipment for cereal chemistry and technology laboratories; and National Walking Sprinkler, which makes self-propelled lawn sprinklers for home and commercial use. For years, TMCO managed production with a basic ERP system and a separate accounting software package. The lack of data integration between the two led to ongoing problems in inventory management, scheduling, purchasing and accounting.
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“Our old system was easy to use but had very few controls,” recalls Rafed Rida, IT and Purchasing Manager for TMCO. “This allowed each department to operate independently rather than working together as a whole, and led to a lot of duplicate data entry, which wasn’t very reliable. We acquired Global Shop Solutions to bring everything under one umbrella and get control over our shop floor.”
Centralizing Data Input Centralizing all data entry in Global Shop Solutions ERP software allowed TMCO to operate as a unified company rather than a collection of competing departments. For example, order entry used to be a random process. Now, when customers send in an RFQ one person creates the inventory part number, router and BOM in Global Shop Solutions ERP software and sends them to each department to move forward with their part of the production process. As a result, new order entry is performed the same way every time, saving time and eliminating manual errors. “When we consolidated everything in Global Shop Solutions, we met with some resistance at first because each department was used to doing it their own way,” says Rida. “But once people saw how much work it took off their plates, they quickly got on board. The beauty of centralizing all data input is that when a process is right or wrong, it’s consistently right or wrong, which makes it easy to identify and correct problems when they occur.”
Getting a Handle on Inventory With tighter controls over data input, TMCO next tackled the issue of inventory management – starting with cutting down on excess material purchases. TMCO does a lot of nesting, with often results in extra material left over at the end of a job. With Global Shop Solutions ERP software, the purchasing personnel use the materials requirement report in the Auto Purchasing feature to identify which materials they will cut a purchase order for. Then they send the information to people on the floor to verify or change the quantities based on the amount of leftover materials. That way, purchasing can adjust inventory in the moment and avoid buying materials they don’t need. On the finished goods side, Global Shop Solutions ERP software’s online updates enable personnel to catch inventory problems right away. For example, if the error log indicates that a material did not issue to a particular job, Rida sends an email to the department with the job number so the supervisor can take appropriate action. “Most of our problems come from employees forgetting to WIP a part or component to finished goods to weld it,” says Rida. “With Global Shop Solutions, we
can catch these problems in real time, giving us much more control over inventory.”
Complete Traceability Many of TMCO’s customers require 100 percent traceability for their parts. Global Shop Solutions ERP software’s lot-to- lot traceability options help to simplify this process. When creating work orders, the ERP software provides the option to indicate when a part requires lot-to-lot traceability. When the option is selected, the system automatically creates a lot based on the job number, and then adds a unique suffix for that particular part. At any point in the production process workers can instantly identify which work order the part was run on and what materials were used. “Global Shop Solutions also helps with producing the certificate of conformance that confirms we did everything based on the purchase order,” says Rida. “We keep all the data organized around the work order, so when a customer asks for a full audit all we have to do is print the documentation. It’s fast, easy and accurate.”
Accurate Purchasing and Scheduling Centralizing the purchasing process in Global Shop Solutions ERP software has enabled TMCO to restrict access for tighter purchase order and accounts payable controls. “We used to have a problem with people paying vendors without looking at the purchase orders,” says Rida. “Now, all purchase orders are issued by a single department, so we don’t have to worry about unauthorized purchasing. Department managers can still cut and approve requisition forms, using an internal tracking number. But Global Shop Solutions gives us a consistent confirmation process for every vendor in the system. Our purchasing department has never been more effective or efficient.”
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TMCO added a new 70,000 sq. ft. building to manufacture larger parts and trailers, and this includes a fully automated blast and wash booth, paint (wet and powder) and oven booths, welding and assembly capabilities.
Meanwhile, TMCO has made great strides in scheduling efficiency. Using the Advanced Planning & Scheduling (APS) application, planners regularly monitor and analyze the schedule to prevent capacity overloads of personnel and workcenters. APS also makes it easy to determine proper lead times to ensure materials are ordered in time for each job.
Company-Wide Improvements Global Shop Solutions ERP software’s ability to simplify operations in every area of the business gives TMCO the improved efficiencies it needs to compete more effectively in today’s global markets. Financials are more accurate, with all costs, profits, payroll and other operating expenses tracked in one integrated program. Constantly reviewing work orders to issue or reverse-issue material and edit work order details has created a smoother workflow with far fewer hiccups. The Customer Relationship Management application enables sales reps to provide faster service by instantly accessing all information about a job or customer from one screen. Even the quoting process has become more efficient with the ability to analyze different price breaks and gross profit percentages to identify margins that will satisfy the customer and the company.
the real-time status of each job, including where it’s at and who’s working on it.” “If it’s a raw material, I can enter a sort code and see all the related part numbers,” he says. “If it’s a manufactured part, I can see all the customer sales orders with all the jobs and their due dates. And I can do all this without going back and forth between different modules or screens.” Supply & Demand even helps with the quoting process, allowing Rida to quickly access sales, inventory, and PO history for a part to see when and how much prices fluctuate. This helps to avoid getting underbid on jobs by ensuring that all pricing is accurate and up-to-date. “In today’s markets, you have to be fast, efficient and accurate,” concludes Rida, “and that requires having reliable data you can trust. With Global Shop Solutions, we can track every step of the process from order entry to purchasing to the invoicing of product. As long as we enter the data correctly, we know we can trust it.”
ABOUT GLOBAL SHOP SOLUTIONS: Family-owned and family-run, Global Shop Solutions built its legacy of trust the way it should be done - by following through. The company continues to do what they say they are going to do, often exceeding
Total Shop Floor Control with Supply & Demand
their customers' expectations. They have become their trusted partner
When it comes to improving shop floor control, Rida gives much of the credit to Global Shop Solutions ever-popular Supply & Demand screen in the Inventory application. “Supply & Demand is awesome!” he exclaims. “All you have to do is enter the part number and it provides everything you need. You can see all the open purchase orders, which jobs will use those materials, and the due dates. From there you can drill down to see
in their long-term success by building a robust ERP software system,
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backing it up with comprehensive training and delivering exceptional customer service. Additionally, Global Shop Solutions implementation success rate is one of the highest in the industry. For more information, visit www.globalshopsolutions.com
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Industry Insight
How to Choose the Best Drill Type for the Next Job Deciding between solid drills or replaceable insert drills By: Deborah Froelich and Rob Brown
H
olemaking is a common procedure in any machine shop, but selecting the best type of cutting tool for each job is not always clear. It is best to have a drill that caters to the workpiece material, produces the specs required and provides the most profit for the job at hand. When it comes to the variety of jobs manufactured in machine shops, there is no “one-drill-fits-all.” Fortunately, the process can be simplified by considering five criteria when choosing between solid drills and replaceable insert drills.
ease of cutting edge replacement is irrelevant. For a short run, the replaceable tool is likely to have a higher initial cost than a solid drill, so it may not pay dividends to invest. Lead time can be better for a solid tool as well, depending on the source for these products. With solid carbide drills, efficiency and cost-savings can be maintained when machining a wide range of holemaking applications.
Is the Next Contract Long-Term or a Short Run?
How Much Stability is Required for This Job?
If the answer is running a long-term, repeatable process, invest in a replaceable insert drill. Commonly referred to as a spade drill or replaceable tip drill, these drills are engineered so that machine operators have the ability to change out the worn cutting edge quickly. This reduces the overall cost per hole in high production runs. The initial investment of the drill body (insert holder) is compensated quickly by the reduction of cycle time and cost of replacing inserts versus the cost of new solid tooling. Simply put, speed of changeout coupled with a lower long-term cost of ownership makes replaceable insert drills the better choice for high production jobs. If the next project is a short run or custom prototype, then a solid drill is the better choice due to the initial low cost. Since it is not likely that the tool will wear out while machining smaller jobs, the
Consider the dimensional stability of a reground solid tool versus replacing the worn cutting edge with a fresh blade. Unfortunately, with a reground tool, the diameters and lengths of the tool no longer match the original version; it is smaller in diameter, and the overall length is shorter. The reground tool is used more often as a roughing tool, and a new solid tool is needed to meet the required finished dimensions. By using the reground tool, another step is added to the manufacturing process to make use of a tool that no longer satisfies the finished dimensions, thus increasing the cost per hole in each part.
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34 IMD MARCH 2021
How Important is Performance for This Particular Job? Machine operators know that solid drills can be run at higher feeds than replaceable tools of the same diameter. Solid cutting tools are stronger and more rigid as they have no connection to fail over
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time. Nevertheless, machinists opt to use uncoated solid drills in order to reduce time invested in regrinds and lead times on reorders. Unfortunately, using uncoated tools reduces the superior speed and feed capabilities of a solid cutting tool. At this point, the performance gap between solid drills and replaceable insert drills is almost negligible.
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The job size, initial cost of the tool, downtime for changeouts, regrinds and touch-offs, and number of steps in the application process are all variables in the cost of ownership equation. Solid drills are a smart choice for short runs due to their lower initial cost. Generally, small jobs do not wear a tool out before they are complete, meaning there is no downtime from changeouts, regrinds and touch-offs. A drill designed with replaceable cutting edges can offer a lower cost of ownership over the life of the tool for long-term contracts and high production runs. The savings start when the cutting edge is worn or damaged because there is no need to order the whole tool—only the insert (a.k.a. blade). Another cost savings variable is the amount of machine time saved or spent when changing out cutting tools. The replaceable insert drill’s diameter and length are not affected by changing out the cutting edge, but since the solid drill needs reground when it is worn, solid tools should be touched off when replaced. This is a minute that parts are not being produced. The last variable in the cost of ownership equation is the number of steps in the holemaking process. Replaceable insert drills can usually complete the process to spec in a single operation. Many applications that incorporate solid drills add a finishing operation after using the reground tool to meet the job’s requirements, creating an unnecessary step that adds machining cost to the part produced. Overall, most machine shops need a good selection of drill types. Many industrial tooling suppliers offer expert guidance in selection of the best drill for a particular job, and tooling manufacturers have free resources for determining the cost per hole to help aid in the decision process.
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ABOUT ALLIED MACHINE & ENGINEERING: Allied Machine & Engineering is a leading manufacturer of holemaking and finishing cutting tool systems. Allied devotes its advanced engineering and manufacturing capabilities to creating the widest selection of value-added tooling available to metal-cutting industries around the world. Their tooling solutions deliver the lowest cost per hole in a wide range of drilling, reaming, burnishing, threading, and boring applications. Located in Dover, Ohio, Allied’s precision holemaking technologies provide end users world-wide with the highest level of performance. Precision engineering and expert application support make Allied the first and best choice for solving complex metal-cutting challenges.
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IMD 35
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.
Launch of New Aisle Master Order Picker: Aisle Master-OP
T
he NEW Aisle Master-OP (AME-OP) is a pioneering stand-on electric powered model that combines the advantages of a narrow aisle articulated forklift and an order picker for versatile operation in warehousing applications.
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The development of this model was influenced by customer feedback - as has often been the case with Combilift’s innovations - as well as the recent soaring growth of e-commerce. “Customers already using the Aisle Master for space saving, storage and
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efficiency in their warehouse asked if we could redevelop the Aisle Master to meet their ever-growing demand for order picking customised orders”, said Combilift CEO Martin McVicar. Research and Development carried out in 2019 and 2020 has created the Aisle Master-OP. The main feature of this unit is the step-through operator compartment which has design copyright protection (European Design Registration No. 002676809-0001) across multiple markets worldwide. The low floor height of just 11-inches enables convenient, single step access from both sides of the truck which speeds up order picking compared to the operator having to get on and off from a seated position. The AME-OP truck has all the key advantages of the conventional Aisle Master - indoor/outdoor, for loading/offloading and for stock replenishment at other times during shifts when order picking is complete. The Aisle Master-OP is available in a number of variants, with lift capacities from 1,500kg to 2,500kg, lift heights up to 12.1 meters and can operate in aisles as narrow as 1650 millimeters. It features a patented chain steering system (EU Patent No. 3008008), which allows the truck to articulate more than 205 degrees, with an inline drive motor and front drive axle assembly, all of which enable narrower aisle operation. The multifunctional programmable joystick control lever in the operator compartment, which includes controls for the hydraulics and traction, is adjustable to enable comfortable and ergonomic working conditions for operators of all sizes. The Operator Presence Detection floor pad engages the parking brake automatically when the operator steps off the truck to carry out Order Picking. “Before we officially launch any new model, Combilift carry out extensive field testing on customer’s sites, this was the case with the Aisle Master-OP”, said Martin McVicar. The AME-OP is now a production model within Combilift, with units currently in build for customers in the United States and in New Zealand - one of which is Sorted Logistics based in Christchurch New Zealand, a third-party logistics provider and freight forwarder who will be receiving eight AME-OP units shortly. “This is a major innovation in the warehousing sector,” added Martin, “and the versatility to use the one Aisle Master for multiple applications - narrow aisle operation, truck to rack handling, bulk picking and item order picking - will result in strong demand for this new product in our home and export markets around the world.” » For more information, visit www.combilift.com
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IMD 37
Suhner Offers Efficient Machining with Special Guards Suhner Industrial Products Corp. (Rome, Georgia) is proud to introduce machining units with special guards that protect mechanical and electrical components against contamination from fiberglass dust and fibers, as well as dust from composite and 3D printed products. Suhner offers automated drilling, boring, tapping, threading and other tools for high-production environments on these products throughout North America. When drilling high quality holes into sheet metal composites and dissimilar material stacks of resin bonded fibers or 3D printed polymer substrates, for example, these dust-protected machining units are an ideal solution. They are universal and can be positioned everywhere alongside the workpiece for precision, automatic machining. Regardless of the complexity of the workpiece or the number of operations that need to be performed, all machining units work at the same time and only the longest operation defines the total cycle time, when the units are used in multiple setups. Any number of Suhner machining units can be applied from different directions and perform all necessary operations at the same time. Additionally, more operations in a smaller footprint lead to greater time savings, while standard and customized solutions are offered through an optimized modular component system from Suhner. These robust machining units have myriad applications in the automotive, RV, building, appliance, aerospace and electrical industries. » For more information, visit suhner-machining.com
COXREELS® Extreme Duty XTM Series Sometimes Heavy Duty or Industrial Duty is not enough. Sometimes the job calls for the toughest of the tough. Sometimes, the application is just extreme. For years COXREELS has supplied heavy duty reels with triple axle supports and solid ¼-inch plate bases for demanding applications and environments. We engineered strength with features, balancing performance with cost, bringing suitable solutions for many market sectors. Some industries still demanded more. Some industries, similar to mining, heavy equipment, lubrication, or other off-road industries work in such demanding remote environments, all of the best features are needed with the most robust structure possible. COXREELS is proud to introduce the Extreme Duty XTM Series spring rewind reel. Born from the coalescing fires of the highest strength springs, stainless steel rollers, dual sintered bronze bearings, multiple axle supports, and welded box frames, the XTM Extreme Duty Reel combines the ultimate features into the world’s most robust reel solution. As with all COXREELS spring rewind reels, the XTM Series will satisfy your application’s hose management needs and is USA made with COXREELS legendary quality, just in a more impervious package than previously available. » For more information, visit www.COXREELS.com
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Caldwell Beams for Schneider Electric Paint Plant Rockford, Illinois-based Caldwell Group Inc. has customized two 500-pound. capacity adjustable lifting beams for a Schneider Electric plant in Columbia, South Carolina. The beams, which measure 44-inches long, 5-inches wide, and 2-inches high, are used by the energy management and automation company to lift 300-pound circuit breakers in and out of electric switchgear during the final stages of testing, prior to shipment. The circuit breakers are produced in a separate area of the paint plant from the switchgear. Once in the testing zone, the breakers must be lifted into the switchgear for testing, utilizing the beams. The beams are rigged beneath the hook of an electric overhead traveling (EOT) crane and operated by pendant control. “The beams have been fantastic. They secure the large load of the circuit breakers without issue and make the environment safe to work around,” said Erich Lanz, upstream planning leader, global supply chain at Schneider Electric. Caldwell also supplied bottom ‘lifting jigs’ that are designed to fit each circuit breaker. The placement and spacing of the points, along with the jig concept, were driven by Schneider; Caldwell ensured the solution met ASME (American Society of Mechanical Engineers) BTH (belowthe-hook) standards. » For more information, visit www.caldwellinc.com
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Schweiss Doors Introduces Superstructure, Triple-Leg Stand-Alone Hydraulic Door Design The new Superstructure Triple-Leg Stand-Alone Door design from Schweiss Doors is truly one of a kind. This trailblazing tripod leg design transfers the door weight to the footings that support the hydraulic door, eliminating the need for additional side columns from the building manufacturer, offering a significant building cost reduction. The doorframe mounts on the new Triple-Leg Stand-Alone, self-supported doorframe, eliminating the need for the building manufacturer to incorporate a building truss or building header to support the hydraulic door. » For more information, visit www.bifold.com
char-lynn hydraulic products low speed high-torque motors… The Char-Lynn
motor range consists of three major types based on the valving used to distribute fluid through the Orbit gear set (geroler or gerotor), Spool Valve, Disc Valve and VIS (Valve-in-Star). A variety of displacement sizes are available in each of the three motor types to provide a wide range of speeds and torques.
steering control units… offer these advantages: • Minimal steering linkage reduces cost, provides design flexibility. • Complete isolation of load forces from the control station. • Continuous, unlimited control action with low output torque. • Wide selection of control circuits and meter sizes. • Works with many kinds of power steering pumps or fluid supply. gear pumps… Eaton Series 26 gear pumps with 13-tooth gears minimizes flow ripple to reduce noise and vibration. Bearing lubrication system uses inlet oil rather than high pressure oil, improving volumetric efficiency and power output. The 13 available displacements and many mounting configurations provide for an easy retrofit. Other series available. 7355 N. Lawndale Ave., PO Box 6, Skokie, IL 60076
Phone: 847-676-2910 Fax: 847-676-0365 www.macmhydraulic.com
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ABB Launches Condition-Based Maintenance Service ABB’s new Condition-Based Maintainance (CBM) service enables robot users to create a preventive maintenance schedule for individual or robot fleets based on real-time operational data, to optimize productivity and minimize downtime. CBM uses real-time data on robot operations to help identify any potential issues that could affect performance, including duty, speed, acceleration, and gearbox wear. These variables are compared against other robots in ABB’s worldwide robot database to calculate the likelihood and timeframe of a potential fault or failure. Aimed at customers with large fleets of robots, ABB’s CBM tool can advise whether remedial action is required, involving either repair or replacement of affected parts. » For more information, visit www.abb.com
Custom Machine and Tool Co., Inc. Has Broken the Size Barrier Required maintenance and constant adjustment of timing pulleys in confined spaces is a challenge. The solution is simple: Custom Machine and Tool Co., Inc. recognized the challenge and met it with the Concentric Maxi Torque. The Concentric Maxi Torque is small-spaceprecise. Custom Machine and Tool Co., Inc.’s compact 'tight fit' design eliminates the expense and time lost due to shaft modification or extended hubs associated with older generation designs. Virtually maintenance free, once in place, there are no further adjustments required because the Concentric Maxi Torque remains secure, thus eliminating any degree of shaft damage or eventual misalignment. Their keyless hub-to-shaft connection device has superior features and benefits compared to other connection systems such as keyways, pins, set screws, clamp collars, and other tapered shaft locking devices. » For more information, visit www.cmtco.com
ANCA Announces a New Era of Automation: Intelligent Solutions for Maximizing Productivity 24/7 ANCA’s new product AIMS solution answers the market needs with over 70 percent of ANCA customers now seeking machines with robotic functionality. AIMS offers modular functionality that can be adapted to each factory’s needs; from smaller scale, data-based options to the full AIMS setup across a series of machines. The system delivers a connected tool production process - transferring tools between operations with the AutoFetch robot; fully automating tool measurement and process compensation using AutoComp and managing data via the AutoSet hub. » For more information, visit www.anca.com
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IMD 41
Bystronic Inc. and MSS Nitrogen Inc. establish Strategic Partnership
ATI Industrial Automation has developed CRX-Ready End-Effector Kits, providing FANUC CRX cobot users a simple and effective way to increase the flexibility of collaborative robotic automation. These all-in-one packages include robust options for automatic tool changing, force sensing, and material removal, and enable tasks such as assembly, machine tending, part inspection, surface preparation and others to be implemented and executed easily. CRX-Ready End-Effector Kits include everything needed to get FANUC CRX cobot applications up and running. In addition to the end-effector, the kit features all the hardware and software required for system connection.
NitroCubeTM is the most compact Nitrogen Generation system on the market and provides the guaranteed lowest cost and highest purity for Nitrogen. NitroCube is ideally suited to meet the demands of today’s ever-increasing Fiber laser cutting requirements. Typical Nitrogen purity generated by the NitroCube is 99.999 percent and systems are carefully sized using information based on user consumption figures, assuring correct flow and storage capacity. Bystronic NitroCube and NitrO2 products powered by MSS, offer increased productivity, enhanced edge quality, reduced cost, and maximum profitability for the end user with minimal floor space requirements.
» For more information, visit www.ati-ia.com/CRX
» For more information, visit www.bystronic.com
ATI Now Offers CRX-Ready End-Effector Kits
Jergens Expands Its Zero Point Systems With New Pneumatic Subplates And Multi-Pull Stud Fixture Plates The first set of additions includes a choice of six different pneumatic subplates, each featuring pre-installed low pressure pneumatic clamping modules. The pneumatic subplates are constructed of Fremax 15 Steel (or equivalent) and include quick connects for changeover speed and porting for blowout in between machining cycles. System repeatability is less than 0.005 millimeter (0.0002 inches). The second set of additions is comprised of aluminum or steel fixture plates with pre-installed pull-studs. Jergens ZPS allows customers to fix, position and clamp tooling or workpieces, all in a single step to reduce part changeover time with no loss in accuracy. » For more information, visit www.jergensinc.com
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AMF Marking and Cleaning Tools Now Available From Platinum Tooling Technologies, Inc.
Coupling bolts used for live tooling on lathes are subject to relaxation, which occurs as a result of inadequate pre-loading of the bolts during installation, or to rough or inaccurately machined coupling faces–resulting in misalignment. This causes excessive vibration, which puts an unnecessary load on bearings, and curtails operation at full power. In response to a special order request, JM Performance Products, Inc. has recently expanded their product offering to include coupling bolts for live tooling on Mazak Corporation CNC lathes. These new pull bolts fully incorporate Mazak’s specifications and are uniquely manufactured to implement JMPP’s patented High Torque retention knob standards from 9310H material.
AMF marking tools are used for the permanent marking of workpieces made from all types of metal and thermoplastic substrates. These tools can function with or without rotation and usually without height adjustment on the spindle, resulting in a high-speed, highly efficient marking process and no degradation of the substrate. AMF cleaning tools are used for the cleaning of workpieces, tooling and the interior of CNC machines. Using through spindle coolant or compressed air, the cleaning tool removes swarf and other debris from workpieces, clamping tools, rotary tables and other fixtures before the next workpiece blank is loaded.
» For more information, visit www.jmperformanceproducts.com
» For more information, visit www.platinumtooling.com
Coupling Down On High Torque Technology
New High-Inertia 1FK7-Hi Servomotors Added To Siemens Offering The higher rotor inertia of this design makes the control response of the new 1FK7-HI servomotors highly robust and suitable for high- and variable-load inertia applications, including the feed and auxiliary axes on machine tools, as well as winders and unwinders on converting, packaging and printing equipment. A mechanical decoupler between the motor and encoder shaft protects the encoder from mechanical vibrations, providing a long service life. In cases where the encoder needs to be exchanged, the device automatically aligns the encoder signal to the rotor pole position, enabling feedbacks to be changed in the field in less than five minutes. » For more information, visit www.usa.siemens.com/motioncontrol
C-FRAME PRESSES • 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.
HYDRAULIC MACHINES OF IOWA A Division of Betenbender Mfg. Inc
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IMD 43
Surplus Buying and Selling
Longer Service Life with Oil Shear Technology
MagnaShear™ Maintenance-Free, No-Adjustment Crane Brakes Eliminate Downtime
F
orce Control Industries presents a maintenance-free, no-adjustment crane brake that virtually eliminates crane downtime. The MagnaShear™ motor brake employs oil shear technology, providing longer service life in demanding applications like the frequent start/ stop cycles seen on cranes, hoists, and winches. Proven oil shear technology transmits torque between lubricated surfaces – thereby eliminating wear on friction surfaces. A patented fluid recirculation system dissipates heat – eliminating heat build-up which is the most common problem in dry braking systems. Elimination of the wear significantly increases service life and virtually eliminates adjustment which also elongates maintenance intervals. An anodizing plant cut preventative maintenance by 2 hours per week and eliminated $8000 in annual parts expenditures by switching from dry brakes to MagnaShear™ motor brakes. In addition to cranes, winches and hoists, they are ideal for applications where the motor is reversed each cycle such as loader/unloader conveyors, rail car spotters and dumpers, ship and rail car loading conveyors, trippers and pallet return conveyors. The oil shear technology also provides a smooth “cushioned” stop which reduces shock to the drive system, further extending service life of downstream components. The totally enclosed MagnaShear™ brakes are impervious to moisture, dirt and dust that is common in concrete block plants as well as asphalt shingle manufacturing, coal, bulk materials handling, forest products manufacturing, and more.
How Oil Shear Works Unlike dry brakes, oil shear technology includes a layer of automatic transmission fluid between the brake disc and the drive plate. As the fluid is compressed, the fluid molecules shear – thus imparting torque to the other side. This torque transmission causes the rotating discs to decelerate against
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44 IMD MARCH 2021
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the stationary plates bringing them down to stop. Since most of the work is done by the fluid particles in shear, wear is virtually eliminated. Elimination of wear also eliminates the need for adjustments which are common for dry braking systems. In addition to transmitting torque, a patented fluid recirculation system helps to dissipate heat which is the major problem with traditional dry brakes. Along with heat removal and torque transmission, the fluid serves to continually lubricate all components of the oil shear brake, elongating their service life. MagnaShear™ brakes with oil shear technology provide significantly longer service life, characterized by virtually maintenance-free operations.
motor for severe duty applications. MagnaShear™ motor brakes can be furnished to fit a NEMA or IEC frame motor, as a complete motor and brake assembly, or to mount on a machine frame or other special mounting configuration. These proven motor brakes are totally enclosed from outside contaminants, with seal integrity for harsh and washdown environments. A modular design/assembly allows for ease of servicing and maintenance.
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and clutch brakes for OEMs in diverse applications. Their manufacturing campus includes three manufacturing facilities with over 100,000 square feet of manufacturing space along with engineering, design, customer support and administrative offices. For additional information contact Force Control Industries, Inc., 3660 Dixie Highway, Fairfield, OH 45014, or visit www.forcecontrol.com, e-mail sales@forcecontrol.com, or call (513) 868-0900. INDUSTRIAL MACHINERY DIGEST.COM
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IMD 45
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