IndustrialMachineryDigest.com | May 2022
North America’s Manufacturing Resource for Industry Professionals Since 1986
» Machine Shop Utilizes Forging Press to Reduce Costs of Titanium Parts » 10 Tips For Achieving Material Handling Safety » Siemens Brings its Portfolio of Solutions and Services to the Fabrication and Additive Manufacturing Industries » Mobile Robotic Equipment Boosts AMR Performance at TE Connectivity » Diffusion Bonded Printed Circuit Heat Exchangers for Severe Environments » The Robotic Edge: Workflow Optimization for Market Advantage
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Table of Contents
COLUMNS
12
BUSINESS 4.0 Machine Shop Utilizes Forging Press to Reduce Costs of Titanium Parts By: Del Williams
16
TALKING SHOP Jeff Burnstein — President, A3 Association for Advancing Automation
22 FEATURES
22 24
MANUFACTURING SHOWCASE Park Engineering Upgrades Machining and Measuring Capacity for Larger Parts
WORKFORCE DEVELOPMENT Why You Must Be A Trusted Advisor To Candidates Too By Jeremy Eskenazi, SHRM-SCP
30 34
NEW TECH Mobile Robotic Equipment Boosts AMR Performance at TE Connectivity
INDUSTRY INSIGHTS The Robotic Edge: Workflow Optimization for Market Advantage By: Chris Caldwell, Product Manager at Yaskawa America Inc. – Motoman Robotics Division
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SAFETY & MAINTENANCE 10 Tips For Achieving Material Handling Safety By: Tim Massey — UK Sales Manager at FlexQube
DEPARTMENTS
6 8 42 46
EDITORIAL DIRECTIONS
49 50
CLASSIFIEDS
PROCESS Diffusion Bonded Printed Circuit Heat Exchangers for Severe Environments Compact printed circuit heat exchangers (PCHE), produced through a diffusion bonding process, surpass traditional alternatives in extreme temperature and pressure environments
38
18
INDUSTRIAL FABRICATION & AUTOMATION Siemens Brings its Portfolio of Solutions and Services to the Fabrication and Additive Manufacturing Industries
26
18
INDUSTRY NEWS PRODUCT SHOWCASE SURPLUS BUYING & SELLING
ADVERTISER INDEX
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Editorial Directions We are living in an age of professional transformation. Manufacturers, in particular, are drinking out of a firehose when it comes to staying abreast of all the new equipment, services, and technologies that seem to be emerging by the day. How are you to choose the additive machine, preventive maintenance service, or process management system that will best benefit your operation, and not be outdated six months after installation? I’ve seen this same thing happening in publishing. New content management systems are constantly being introduced, and feeding ever-evolving social media platforms now competes for time with the bedrock skills still required to produce a print magazine—researching, interviewing, writing, editing, proofreading. It’s a constant climb up the learning curve to adopt and utilize these new technologies, only to know the whole social media landscape will keep changing and growing. For manufacturers, scalability and upward compatibility help keep newly-purchased systems updated. It seems like a good idea to factor these concepts into any capital investment; do these machines and software systems allow for expansion and growth, keeping you at the forefront of your particular market? Another thing I have noticed is how much more important the relationship between manufacturer and supplier has become. Sales professionals are more knowledgeable than ever before, staying on top of ongoing developments and providing thoughtful solutions to their customers. This synergy has helped the manufacturing industry as a whole to weather recent challenges and emerge equipped to not only compete but succeed in this new economic and technological landscape. I look around me and see trade shows booming, travel beginning to open up, and companies poised to utilize the knowledge they’ve gained by surviving global economic upheaval in the dark shadow of a pandemic. All I can say to my friends out there, and to those I look forward to meeting, is Bravo!
SERVING AMERICAN MANUFACTURERS FOR OVER
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INDUSTRIAL MACHINERY DIGEST (ISSN 1542-5223) is published 12x per year by Source 360 Media. POSTMASTER: Please send change of address to INDUSTRIAL MACHINERY DIGEST, 3590-B US Hwy 31 South, PMB 233, Pelham, AL 35124. Printed in the U.S.A. SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the U.S. to qualified individuals. Publisher reserves the right to reject nonqualified subscribers. Oneyear subscription to nonqualified individuals in the United States: $9600. Single copies available (prepaid only) $2000 each.
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Industry News
INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industries top companies. WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com
BIG DAISHOWA’s Michael Herman Promoted to Vice President Sales
integration space will provide world-class automation and robotics solutions to the region and create approximately 140 jobs in the next five years. The new facility opened for business on March 1, 2022. With the new facility, the automation systems integrator provides U.S. customers greater access to its intelligent automation and robotics services and can more easily serve its growing roster of core customers in the region. In addition to automation and robotics integration, the company’s offerings also include material handling, automated guided vehicles, and controls systems integration. The facility further positions JMP as a global leader in the growing $500 billion automation market. “We’re energized by the growth that we’ve experienced and the opportunity that it has afforded us to move forward with this new facility,” said Ray English, commercial leader of JMP’s Automation & Robotics Division in Arkansas. “This investment in Northwest Arkansas not only allows us to better serve our existing customers in this area, but it also gives other potential customers in the U.S. easier access to the automation services JMP provides.” Many manufacturing and process industries continue to experience staffing and labor related challenges, which have only been exacerbated by the pandemic. These challenges have introduced safety and sustainability concerns and presented opportunities for automated solutions to stabilize manufacturing operations. This announcement by JMP demonstrates its commitment to continued growth in addressing these challenges head-on through increased capacity and capabilities across a continually expanding footprint. In addition to expanding its reach and providing greater access to its customers, the new facility is positioned to provide unique, ongoing skills development, technology
BIG DAISHOWA Inc. announces Michael Herman has been promoted to Vice President Sales. In this role Herman oversees the BIG DAISHOWA sales team, and supports the company’s Michael Herman distribution network and machine tool builders throughout North America. “Mike’s dedication and extensive knowledge of the industry has been an invaluable asset in growing the company. The role of Vice President Sales is an expansion of the work Mike has already accomplished,” says BIG DAISHOWA President/COO, Jack Burley. “In this role, I look forward to continuing supporting manufacturing and sharing my knowledge to help companies not only reach, but surpass their productivity goals,” says Herman. Herman brings 40 years of experience to this role, including 10 years at BIG DAISHOWA Inc. (formerly BIG KAISER Precision Tooling Inc.). During his tenure at the company, Mike has continued to build and develop relationships with the sales team, distribution and business partners, with a personal commitment of promoting a higher performance guarantee.
JMP Opens New Automation and Robotics Production Facility in Northwest Arkansas JMP Solutions recently announced that construction is complete on its new state-of-the-art Automation & Robotics facility in Northwest Arkansas and that it is open for business. The 20,000-square-foot manufacturing and
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training and continuing education to better recruit and maintain high-quality talent for the area. “JMP Solutions is a values-oriented and people-centric company,” said Mark Fulmer, who was recently appointed director of operations for the new Arkansas facility. “We look forward to partnering with local universities and trade schools to attract the best new talent, and we are wholly committed to providing an enriching work experience for the entire team.” JMP’s close relationships and partnerships with industry leaders in the region, along with the proximity of the University of Arkansas and other premiere vocational and technical schools, will make Northwest Arkansas a top training and development sphere for the next generation of automation innovators. Based in the heart of the Ozark Mountains, JMP’s new facility is the latest addition to a thriving economic region with enterprise-class businesses and an unparalleled quality of life. Fayetteville is Arkansas’ second-largest city and was named among the country’s top five places to live in 2021 by U.S. News Best Places to Live. It is also home to the University of Arkansas, the state’s largest university. In 2021, DegreeChoices ranked the school 13th among universities with the most graduates working for Fortune 500 companies, and Gartner rated the university’s supply chain management program at the Sam M. Walton College of Business as the best program of its kind in the country. Northwest Arkansas and the Ozark Mountains are home to a wide range of natural attractions, offering an array of outdoor activities that range from cycling, backpacking and hiking to spelunking and boating. Class 4 rapid kayaking and Bull Shoals Lake, with 94,000 acres of water and 1,050 miles of shoreline, are within easy driving distance of JMP’s new 50-acre campus. In August 2021, JMP was acquired by Crestview Partners, a leading private equity firm. The move was the first of many that Crestview anticipates will build a global market-leader presence in intelligent, automated industrial manufacturing with operations in North America, Europe and Asia.
New Group to Drive Innovation in 3D Printing Industries The Photopolymer Additive Manufacturing Alliance (PAMA) will Kick off Activities at RadTech 2022 in Orlando
Chevy Chase, MD (April 8, 2022) The Photopolymer Additive Manufacturing Alliance (PAMA) announces its formal launch as an organization dedicated to the advancement of research and technology in the 3D printing industry. PAMA is a collaboration between the U.S. Department of Commerce’s National Institute of Standards and Technology (NIST) and RadTech, the nonprofit trade association dedicated to advancing ultraviolet and electron beam technology. The field of photopolymer additive manufacturing spans several technologies, including stereolithography (SLA), digital light processing (DLP), liquid crystal display (LCD), and binder jet 3D-printing techniques. These techniques are currently widely used in manufacturing consumer products such as dentistry, jewelry, eyewear and sporting equipment. They also hold great promise for applications in personalized medicine, including 3D printing of tissue scaffolds and bone grafts, and for manufacturing in space. “PAMA’s overarching goal is to better connect the industrial photopolymer supply chain with end user experiences in 3D printing,” says David Walker, Chair of the PAMA Executive Advisory Board and Co-Founder of Azul 3D. “In a widely diversified market, the language we use to describe our technology matters. Our industry's terminology and protocols are not yet well aligned or agreed upon, making it nearly impossible
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for end consumers to make informed and accurate comparisons between the existing technologies. This lack of transparency, coupled with an over-abundance of inconsistent marketing claims, has led to substantive roadblocks in the adoption of 3D printing in a safe and reliable way within manufacturing ecosystems. Simply put – a lack of unified standards and practices is holding Additive Manufacturing and Industry 4.0 back.” PAMA already has commitments from critical institutions and end-users and is now accepting new members. “PAMA will help drive innovation in this critical manufacturing sector by supporting the development of standards and protocols and by providing a forum where members can share research and best practices,” says Dianne Poster, a research chemist and senior advisor at the National Institute of Standards and Technology (NIST). NIST promotes U.S. innovation and industrial competitiveness by advancing measurement science, standards and technology in ways that enhance economic security and improve our quality of life.
Jeffrey Brown Joins Unilog as VP of Engineering Tenured technology leader brings acuity and creativity to his new role at Unilog Unilog announced Jeffrey Brown has been appointed Vice President of Engineering. As a leading provider of powerful, affordable eCommerce solutions for midmarket
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businesses, Unilog is excited to have Brown lead their Engineering team as they continue to evolve and expand their digital technology offerings. "Jeffrey is a well-respected technical leader who has a deep understanding of cloud Jeffrey Brown computing," said Suchit Bachalli, Unilog CEO. "What sets him apart is his creative approach to solving real-world problems. I know he will make a significant contribution to our company and help us take our content and commerce platforms to the next level." Brown spent the last 24 years building a formidable career at Infor where he was responsible for the overall architecture of their SX.e ERP and its subsequent move to the multi-tenant cloud solution, CloudSuite Distribution. Holding various architect, administrator, and managerial roles, Brown's most recent position at Infor was Director of Development. "I love technology and all the challenges that come with it," stated Brown. "I'm thrilled to join Unilog because we share the same passion for disruptive technology, good software design, and customer-driven user experiences."
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Del Williams Technical Writer ABOUT THE AUTHOR Del Williams is a technical writer based in Torrance, California. He writes about health, business, technology, and educational issues. He holds a master's degree in English from C.S.U. Dominguez Hills.
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Machine Shop Utilizes Forging Press to Reduce Costs of Titanium Parts
S
avvy machine shops are adding advanced forging equipment to create precision titanium components at a lower cost, in volume To produce complex titanium parts more cost-effectively, machine shops are increasingly incorporating advanced forging equipment to complement their existing CNC capabilities to create near-net-shaped parts that only require minimal machining. In some cases, the forging process is so precise that no additional machining is required. There are significant advantages to include forging in a machine shop’s repertoire. With recent advances in the controls and automation of hydraulic forging presses, precision titanium parts can be forged to extremely tight tolerances, and at relatively high volume. Forging also significantly lowers titanium input costs by as much as 50%. To forge titanium to precise specifications, however, machine shops require the right equipment with exceedingly tight control of the
production parameters. Fortunately, advances in hydraulic press design, controls, and automation are helping to optimize component quality, production, and price. To cost-effectively produce large, complex titanium parts, Pennsylvaniabased FPD Company, a machine shop that produces aerospace and medical components, decided to invest in a unique new custom press capable of greater control with higher tonnage. “We wanted to increase our forged parts envelope, and that required a larger press with more sophisticated controls for the titanium parts. We already had a 2,500-ton press, which is relatively small for titanium. At the same time, we needed to improve control, quality, and cycle times,” says Jeff Speicher, General Manager of FPD. To achieve its production goals, FPD partnered with Erie Press Systems, a manufacturer of mechanical forge presses and individually engineered hydraulic presses since 1895 that is
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now part of the largest forging equipment supplier in North America: Ajax-CECO-Erie Press. Although Erie Press designed, engineered, and built the system, FPD provided significant input on the design requirements. The result was a customized high-speed hydraulic press capable of producing 3,000 tons at a fully controlled, programmable speed and load profile through full travel. “The custom press, along with our engineering and tooling, allows us to hold extremely tight tolerances consistently when creating titanium parts for the aerospace and medical device industries. With the right equipment, the forgings are extremely consistent, and we can produce near-net shapes that require minimal to no machining. If a part needs additional machining for holes, bores, and other secondary features, we can do that as well,” explains Speicher, adding that FPD provides extensive 5-axis CNC machining services on site.
Precise Control of Forge Stroke, Force According to Speicher, the Erie Press forging equipment is designed with a unique servo hydraulic system that allows greater control of the forging stroke and applied force. The press control modulates the servo proportional accumulator discharge valves to maintain the programmed velocity regardless of the load, ensuring consistent forging performance. This arrangement provides flexibility to forge parts across a wide velocity range not possible with a mechanically adjusted accumulator discharge rate configuration. For some part geometries, the deformation rate of the titanium may require variable velocity profiles throughout the forming process. Altering the deformation rate enables
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FPD to achieve improved die life while creating greater detail by filling the die cavity webs and corners later in the stroke. According to Speicher, the servo-hydraulic system allows extremely high resolution in defining those parameters. Furthermore, the press position controller publishes (to FPD’s plant server) a high-speed plot or digital signature corresponding with each part’s forging cycle for historical records and reference. FPD can also control the press to strike the part at a specific force or to a pre-defined tonnage limit. In addition, the press can stroke to a programmed position within a positional accuracy of less than .01”. Erie Press’s Human-Machine Interface (HMI) allows operators to see how the press functions and anticipate how it should be performing. This is accomplished with dynamic animated models and schematics, live trending, and diagrams. The HMI is a software application that graphically presents information to operators about the state of various processes in a format that looks like the actual machine or display panel. The information can be accessed locally (at the machine) or remotely (within the plant or offsite) via PC, laptop, or smartphone. “Erie Press incorporated a very user-friendly, graphicsbased HMI into the design that can walk even someone unfamiliar with the forging process through it step by step,” says Speicher, adding that the forging press manufacturer’s HMI system is a virtual “digital twin” of the actual machine as it functions. “The press has sensors that monitor the ram position, pump output, valve positions, etc. and all these parameters are monitored in a digital representation of the press. With the HMI, the operator sees how the machine is performing in real-time,” adds Speicher.
The HMI also helps operators monitor what is happening with enough insight to successfully troubleshoot and promptly get the equipment back online when required. For example, operators can quickly “drill down” from a top-level animated schematic to review the performance of specific components, such as valves and pumps, and locate information on part numbers and wiring schemes. Up-to-date PDF technical documents and the schematics of each component on the machine are also searchable and can be quickly displayed as needed. The Erie Press forging equipment incorporates automation that enables the operator to change-out hot dies in less than ten minutes. A forging change-over is completely handsoff, requiring only inputs to the HMI. Titanium billet and workpieces are pre-heated in an electric furnace, while the tooling is pre-heated offline. The operator, working behind an interlock gate system for safety, uses a joystick to transfer the tooling into the press,
which is hydraulicly clamped into place. A barcode is scanned on the production router, which calls up a part-specific forging program in the controller. FPD worked with Erie Press to incorporate safety features such as preventing the program from executing if the bar codes of the toolsets and parts do not match the router, and a safety stroke the operator must execute before proceeding to automatic mode. “Because we produce a lot of short runs, we can set up multiple times a day and this gives us tremendous production capacity,” says Speicher.
Extending Longevity, Lowering Cost Controlling stroke speed has also helped to prolong tool life. “With the hydraulic servo control, the operator can vary the press’s stroke speed with far more control, which prolongs tool life. According to our internal statistics, the new
press has extended tool life by about 50%,” says Speicher. There are also significant cost savings versus the conventional machining approach. “Depending on the part geometry, we can normally reduce unit price in the 30% to 50% range over a hog-out part [machined from bar, plate, or billet]. That is due to using less input material – and titanium is very expensive,” explains Speicher. For machine shops, adding advanced forging of titanium parts to their existing machining capability can not only help to improve production speed and control but also significantly lower input costs – all which boosts the bottom line. Please visit the Ajax-CECO-Erie Press website at www.AjaxErie.com or e-mail them at info-sales@AjaxErie.com. Or, if you prefer, call 814-455-3941. Also, visit the FPD Company website at www.fpdcompany.com or contact Jeff Speicher, Mike McAllister, or Dan Gordon for inquiries at 724-731-2137.
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Talking Shop
FEATURING:
TALKING SHOP WITH: Jeff Burnstein — President, A3 Association for Advancing Automation Could you give us a mile-high view of A3 and how it’s structured? At one time we represented a number of associations devoted to different aspects of robotics and automation. In 2021 we joined them together under the A3 umbrella, which allowed us to speak with one voice and on one website. They were the Robotic Industries Association (RIA), AIA-Advancing Vision + Imaging (AIA), and the Motion Control and Motors Association (MCMA), which have changed to technology sectors within A3. We have also established A3 Mexico, as well as the Artificial Intelligence tech sector. Before, you had to join each association individually, but now when you become a member of A3 you’re automatically enrolled in all of our tech sectors. We now stand at approximately 1,100 member companies.
Describe member benefits, including your activities on their behalf and educational resources. We produce webinars, podcasts, and have a section on our website called “The Vault” which contains hundreds of presentations on subjects that will benefit our members, especially their new employees. We provide a variety of certification programs, which can be accessed online, or at our trade shows. We also conduct onsite training where we will travel to their facilities and speak to groups of any size. We have performed these sessions all around the world, and we tailor the content to each company’s individual needs. We’re an advocate of robot safety, for instance, so we factor that topic into all of our activities. And we represent our members in other ways as well, including standards development and providing input to government agencies working on legislation that will affect our industry as a whole. We developed the American National Robot
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Safety Standard and have official agreements with agencies such as OSHA and NIOSH. We’ve also worked with the Department of Commerce, and I have spoken before Congress on robotics, automation, and AI.
Automate is your flagship show, but you also produce The Vision Show. What does A3 offer at these conferences? Automate has existed in a number of forms since the late ‘70s. For many years we co-located with ProMat, which focuses on warehousing and supply chain issues, in Chicago. But as we both grew, we each needed more space, so we will now be holding Automate June 6-9 at the Huntington Place Convention Center in Detroit. We’ll have about 125 speakers at our technical conference during the show, and these presentations will be non-commercial, discussing issues and processes with no emphasis on a particular company or its
IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
products. And we’ve laid out the show floor in an interesting way, with system integrators right up front. Moving deeper into the show you’ll find areas devoted to robots, machine vision, autonomous mobile robots, and many other areas pertaining to robotics and automation. Various certification programs are available at the show where you can spend 4-5 days attending training seminars, take a test at the end, and leave with a certificate in machine vision or motion control. The information presented at the show will be widely disseminated, beginning with our website. The Automate Show is primarily for end-users seeking more-efficient means of upgrading and streamlining their manufacturing operations. The Vision Show will be held October 10-13 at the Hynes Convention Center in Boston, and it focuses more on OEMs looking for the latest machine vision technologies to incorporate into their products. It resembles the Automate Show in terms of the wealth of information on offer, but these are two totally different conferences. We pay close attention to the presentations and structure of each event with valuable assistance from our member companies, which are very active and engaged in all aspects of A3. Our mission is to act as “the global advocate for the benefits of automating. We promote automation technologies and ideas that transform the way business is done.” We are an advocate for our members, and the industry at large, while also working
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to dispel the confusion surrounding things like AI and machine learning. We’ll be adding more tech sectors in the coming years that will reflect the vibrant growth and innovation constantly being brought to market, and we will continue to stand as a resource for anyone who’d like to learn more about the information and knowledge we’ve gained over the past 48 years. For more information about A3 go to www.automate.org. To learn more about the Automate Show visit www.automateshow.com.
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Safety & Maintenance Courtesy: FlexQube.
10 Tips For Achieving Material Handling Safety
M Tim Massey UK Sales Manager at FlexQube ABOUT THE AUTHOR Works in sales of Heavy Duty, Modular logistics equipment. What brings me joy? Bringing innovation to help improve your processes!
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aking material handling safety a priority will improve the abysmal safety stats the manufacturing and warehousing industries currently have. Discussions on technological advancement across the industrial sector are generally focused on operational efficiency while ignoring the safety of operators on facility floors. Operational safety is also a key consideration for adopting transformative technologies such as industrial automation, which removes humans from dangerous situations. The statistics also show that the traditional ways of protecting operators in industrial facilities need some enhancements. Conventional material handling systems such as forklifts and industrial trucks were responsible for approximately 85% of fatalities and 34,900 serious injuries in the United States. A cursory search of the Occupational Safety and Health Administration records will show that transportation equipment going off-track, inadequate loading equipment, and defective equipment were the major causes of these accidents. The prevalence of accidents associated with material handling safety highlights the need to integrate operational safety tips within facilities. This post will explore some of the more important tips for optimizing material handling safety. These tips will take into consideration every operational process where errors can lead to dire consequences. Thus, tips will be categorized under operational safety tips, technological safety
provisions and tips, and material handling equipment management.
Operational material handling safety tips Building an optimized material handling system and ensuring it is properly operated is a blueprint manufacturing facilities and warehouses can employ to reduce safety-related incidents on facility floors. Stakeholders can improve operational safety by:
1. Optimize capacity and layout planning The capacity of a facility and the state of its shop floor determine its productivity levels, as well as the level of safety that can be expected. A chaotic facility floor will experience traffic when transporting materials, and this is a recipe for disaster. Moving materials while operators zigzag through the pathways of industrial vehicles is also a recipe for disaster. Thus, proper planning is required. TIP: Enhancing operational safety through proper capacity and layout planning is no longer a difficult process. Multiple digital transformation technologies such as simulation modeling software can be used to evaluate operational plans before implementation. A properly planned layout will include dedicated storage areas and pathways for transporting materials that are off limit to operators. IMPLEMENTATION RESPONSIBILITY: The responsibility for optimizing facility capacity and the layout that caters to material handling
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is that of C-level executives. Stakeholders must ensure safety features prominently within the context of improving operations or revenue. Stakeholders are expected to hire experts who can use the appropriate technology to develop optimized plans.
IMPLEMENTATION RESPONSIBILITY: Managers are expected to draft safety policies and implement them through the training of shop floor operators. Providing incentives for departments that adhere to safety policies also incentivizes others to follow through.
2. Implement a safety culture
3. Welcome regulators as consultants
The culture of ‘profitability no matter what happens’ has negatively impacted the implementation of safety within the industrial sector. Putting finances first sends a message across to operators, and that message is ‘we do not really care about your safety, just get the job done’. Implementing a safety first tradition in place puts the rank and file on the side of management and motivates employees to do their best. The LyondellBasell story is an excellent example of how this works. To stave off bankruptcy, the plastics and chemicals refining company hired Jim Gallogly as its CEO. In his first meeting, the new CEO outlined his commitment to safety before discussing the dire financial situation the company found itself in. The focus on safety reduced shop floor accidents, motivated employees, and increased productivity.
The boys in suits or the boys from the government are generally seen as nuisances who make life difficult for operators. Many operators and managers also believe regulators have no skin in the game and do not understand operational dynamics…but this is far from the truth. Regulators are also affected by increasing accident rates as their names are attached to the facilities they visit. Thus, regulators should be welcomed just like the expensive operational consultants you pay a premium to for productivity-related advice.
TIP: Implementing a safety-first initiative reduces an enterprise’s risk of financial loss from safety-related incidents. Safety policies should include developing strategies to deliver material handling safety within a facility.
TIP: The tip is in the title. View regulators from the government as cheap consultants and ensure the recommendations they provide are implemented. IMPLEMENTATION RESPONSIBILITY: The responsibility of welcoming regulators falls on the shoulders of facility managers and supervisors who work directly with operators and order pickers using material handling systems.
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IMD | 19
IMPLEMENTING TECHNOLOGICAL SOLUTIONS TIPS: The digital transformation of the industrial sector supports the application of automated solutions to ease the operational challenges operators face. Some tech-related tips to ensure material handling safety include:
4. Automate the material handling process Removing humans from the material handling process drastically reduces material transportation-related accidents. Currently, two automation solutions that you can use exist. These are autonomous guided vehicles (AGVs) and automated mobile robots (AMRs). AGVs reduce accidents because they have dedicated tracks that do not cross operator pathways, and they can be controlled using wearables when they go off-track. AMRs navigate the shop floor using collision-detection technology that ensures they function at safe speeds and navigate the floor without colliding with objects. TIP: Industrial automation reduces the possibility of human error when material handling systems are in operation. This reduces accidents and ensures facilities are safer for human operators. IMPLEMENTATION RESPONSIBILITY: Project managers and C-level managers are expected to analyze the viability of an automated material handling system to pursue their implementation.
5. Employ remote monitoring The need for supervisors who move from station to station to ensure materials get to specified locations on time has become obsolete. Remote monitoring technology solutions such as IoT and tracking sensors can easily pinpoint the location of material handling equipment and the speed they are moving without putting a human in harm’s way. Remote monitoring solutions are subsets of Industry 4.0 as they leverage the interexchange of data within facilities and data analysis to calculate risk factors. Understanding the risk factors associated with material handling equipment in real-time reduces accidents. TIP: Monitoring material handling systems ensure that materials are properly handled and transported within specified speed limits within a facility. Thus, when transporting heavy-duty materials, supervisors can easily manage transportation speeds to eliminate safety incidents. IMPLEMENTATION RESPONSIBILITY: Stakeholders that decide the utilization of technological solutions within the shop floor are responsible for implementing remote monitoring strategies. Individual safety officers must also be trained to monitor material handling systems to prevent accidents.
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6. Integrate safety implementation technologies In certain scenarios, even automated guided vehicles can go off-track. When this occurs, there must be fail-safe solutions to ensure off-track AGVs can be controlled and brought to a stop without harming workers on the shop floor. Technologies such as wearables provide operators with a means to control errant vehicles to safety without being in their path. TIP: Implement fail-safe solutions to ensure material handling equipment does not cause damage when they go off-track. Technologies such as wearables and IoT devices can help with controlling off-track AGVs. IMPLEMENTATION RESPONSIBILITY: Implementing safety measures is the responsibility of project managers, while operators must be trained to utilize safety implementation technologies when incidents occur. TIPS FOR PROPER MATERIAL HANDLING EQUIPMENT MANAGEMENT: The equipment used to transport materials across the shop floor must be properly managed to forestall accidents and deliver increased productivity. To achieve this, operators must understand the proper processes of handling material handling equipment and taking care of them. The tips provided here can help with proper material handling equipment management.
7. Devise predictive maintenance strategies Industry 4.0 focuses on leveraging historical data to prevent downtime, which can be caused by faulty material handling equipment. Implementing a predictive maintenance strategy ensures faults are easily discovered and mitigated in real-time to forestall unplanned downtime. Predictive maintenance also reduces the possibility of material handling equipment developing a defect while in operation. Unforeseen faults or defects can lead to accidents within the facility. TIP: Ensure predictive maintenance strategies are developed from accurate data analysis with the capacity to accurately predict the need for future maintenance and repairs. IMPLEMENTATION RESPONSIBILITY: Stakeholders are tasked with devising predictive maintenance strategies while repair technicians handle the repair and maintenance activity.
8. Train staff on proper material handling Achieving material handling safety starts with training the employees who utilize manual material handling equipment on proper utilization. Continuous training ensures employees do not make common errors such as running with carts to speed up delivery or pulling a cart from the front instead of pushing. Properly trained staff are more likely to avoid the errors that lead to accidents on the shop floor.
TIP: Outsource staff training to material handling system experts who understand what it takes to properly operate a cart. IMPLEMENTATION RESPONSIBILITY: The training and validation required to ensure material handling safety must be initiated by stakeholders, while the training process should be handled by professionals.
9. Secure transportation routes Securing the routes material handling equipment takes when making deliveries or picking orders to improve material handling safety. Securing these routes means ensuring obstacles do not obstruct pathways and the floors are properly graded and built to support the movement of equipment. The floor should also be properly maintained to ensure snags, holes, and other defects do not get material handling equipment to go off-track. TIP: Implement a route maintenance policy to ensure transportation pathways are always at their optimal condition.
10. Sustained vigilance Implementing every strategy to improve material handling safety without consistently applying these measures reduces their efficiency levels. Sustained vigilance and training and retraining employees are the recommended solution to delivering lasting safety within the shop floor. TIP: Managers must consistently schedule training to ensure everyone remains on their toes where upholding safety measures are required. IMPLEMENTATION RESPONSIBILITY: Everyone that works within a facility and has cause to navigate the shop floor must be responsible for upholding implemented safety strategies.
Conclusion Corporate leaders in the industrial sector must reassess what safety means and the importance of material handling safety to deliver sustainable, accident-free environments. Making safety a priority is guaranteed to improve the abysmal safety statistics the manufacturing and warehousing industries currently experience.
IMPLEMENTATION RESPONSIBILITY: Floor managers and supervisors are tasked with inspecting material handling systems to ensure the pathways are secure.
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IMD | 21
Manufacturing Showcase
Park Engineering Upgrades Machining and Measuring Capacity for Larger Parts
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talybridge-based engineering company Park Engineering has significantly increased the size of parts it can machine and subsequently measure on a coordinate measuring machine (CMM). It follows the installation at the start of 2022 of two new machines, a Spanish-built Correa Fox 50 5-axis machining centre having a 5.0 x 3.25 x 1.6 m working envelope, nearly 16% larger than the previous largest machine, and an ALTERA M 30.20.15 CMM with 3.0 x 2.0 x 1.5 m axis travels built by LK Metrology in Castle Donnington, UK. Compared with the largest of three LK machines previously operated by Park Engineering, it offers twice the measuring volume. A member of the tooling division within the Hyde Group in the North of England, Park Engineering specialises in the design, manufacture, assembly and certification of tooling jigs and fixtures for the aerospace, nuclear, defence and automotive sectors, so the company is accustomed to dealing with large components. It also provides a subcontract machining service. When looking to invest in new technology to offer even larger The new Correa 5-axis machining centre at Park Engineering, Stalybridge, producing the capacity, there was a desire to inspect the bigger aluminium freeform surface-profiled part. parts on a 'gold standard' CMM platform rather than which included the retirement of the two older CMMs and rely on portable measuring systems, which may have a larger replacing them with a new, larger machine. Quality manager measuring volume but are usually lower in accuracy. Will Reeves looked at other potential CMM suppliers, which Park Engineering first encountered LK in the mid-1990s is normal practice within the group, but saw no reason to when buying a pre-owned, 10 year old, 2.5 x 1.5 x 1.2m change due to his long-term experience of the reliability of LK capacity G80K. The performance of the machine coupled machines and the excellent service provided by the LK team. with the good back-up provided by LK in maintaining the Reeves said, "In fact, the process only served to equipment's mechanics and its ability to provide control and underscore LK's reputation and reaffirm the trust we have software upgrades prompted the purchase a few years later in them as a preferred supplier. The fact that it is a UK of another pre-owned LK CMM – a 2.0 x 1.0 x 0.8m G80C. manufacturer is an added benefit, as it means that the Both were the mainstay of jig, fixture and tooling inspection in-depth engineering expertise in the factory is local to us not only for the company’s own production but also for a should it be required." growing subcontract customer measurement service. Discussions with LK soon identified the ideal size of the The metrology department continued in this vein, new CMM to be installed, the ALTERA M 30.20.15. Mr Reeves adding a new LK INTEGRA 10.10.8 with a measuring enthused, "The increase in speed and accuracy of the ALTERA volume of 1.0 x 1.0 x 0.8m in 2007 for quality control of M, which is around six times faster and 216% more accurate smaller, tight-tolerance aerospace parts and tooling. The than the oldest of our previous CMMs, was a great selling machine was purchased through Metris, which owned LK point but we were also delighted to have a larger capacity at the time, although the company has been independent CMM with a smaller overall footprint. It is down to the top again since 2018. class LK machine design, incorporating the best of modern All of Park Engineering's activities were at the time materials and technology. " conducted at a factory in Reddish, Stockport, but the In day-to-day operation, the ALTERA M CMM supports the company relocated in the second half of 2021 to larger inspection of large parts with drawing tolerances of typically premises owned by the Hyde Group in Stalybridge, ± 50µm, but is sufficiently accurate to measure smaller parts Cheshire. In the process, the company decided to upgrade down in the 10 µm region. Irrespective of tolerances, LK’s its machining and measuring technologies and capacities,
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IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
The LK INTEGRA 10.10.8 being operated at Park Engineering by inspection department apprentice Daniel Read, who will shortly qualify with an NVQ 3 and an HNC in a new metrology-based apprenticeship via Stockport Engineering Training Association (SETA).
software application CAMIO with its user-friendly operator interface allows CNC programs to be generated either online or off-line for the inspection of batch quantities, further reducing inspection time and cost, especially when CAD models are available. Mr Reeves commented, "Across the broad spectrum of work packages, we have access to CAD models approximately 50-60% of the time, with the remainder being work to print. However, the provision of CAD models is something we are always encouraging our customers to provide, as it minimises the risk of incorrect data being entered
due to human error during the programming process." He concluded, "LK’s CAMIO software also saves time by automatically generating comprehensive reports that we are able to send to our customers with inspected components. The professional appearance of the documentation adds to the perceived professionalism of the service we provide.” “The new metrology platform is significantly more productive than our old G80K and the G80C put together, as well as being more accurate. Along with the INTEGRA, it puts Park Engineering in a good
position to provide metrology support not only to our own production, but also to external customers that want subcontract measurement support now and into the long-term future.”
Established in England in 1963, LK Metrology has an impressive heritage in metrology dating back to the birth of CMM technology. Founded by CMM pioneer Norman Key and his father-in-law Jim Lowther, LK Metrology is credited with many of the CMM industry’s firsts including the first bridge-type design, first OEM to integrate computers, first to use a touch trigger probe, first to develop inspection software, first to use all air bearings and granite guideways, first to use carbon fibre composite spindles, first to use microprocessor-controlled
drive systems, first to produce a truly thermally stable CMM and first to produce a high-accuracy horizontal-spindle CMM. In 2018, LK Metrology was relaunched as an independent CMM manufacturer after several years as a division of Nikon Metrology. Headquartered in the UK, LK's CMM development and production are at the company’s facility in Castle Donington. Sales and support offices are located in the UK, North America, Belgium, France, Germany, Italy and China, supplemented by a worldwide distributor network.
Running the CNC program to inspect and report on the part.
ABOUT LK METROLOGY LK Metrology is renowned for innovative metrology solutions and services. The company’s products, including coordinate measuring machines (CMM), portable measuring arms and metrology software, are used worldwide to control and improve the quality of manufactured components. Its precision technology underpins the process chain from design, development, production and assembly through to quality assurance in global industries such as automotive, aerospace, defence, motorsport, energy, medical and contract inspection.
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IMD | 23
Industrial Fabrication & Automation
Siemens Brings its Portfolio of Solutions and Services to the Fabrication and Additive Manufacturing Industries
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iemens is presenting its full portfolio of machine control hardware, software and cloud-based services to the fabrication industry. The special highlight of this Siemens is the new Sinumerik Motion Control (MC) system — an open, industrial PC-based controller with embedded CNC and PLC in a Windows® 10 environment. Also included are end-to-end solutions for additive manufacturing and digitalization, its high-level flagship Sinumerik 840D sl CNC for robotic application, plus the Manage MyMachines application running on Mindsphere, the Siemens cloud for industry. Manage MyMachines can remotely connect to machine builders and end users as well as Siemens Technical Application Centers located around the globe to show machine status, operating mode and program status in
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IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
real-time. Machine builders and end-users are able to accurately monitor machine performance for their globally installed base or factory production network located around the world. This provides a clear picture for the assessment of machine performance, predictive maintenance and OEE. The latest developments in the Sinumerik 840D sl CNC and its Virtual NC Kernel (VNCK) are included, as well. With Sinumerik Run MyVNCK, machine users can create their own control-specific virtual world by embedding the original CNC kernel into a virtual machine. This allows users to seamlessly plan, verify and optimize their production steps in a virtual environment, while avoiding possible programming errors and collisions. This technology can be applied towards OEM applications in laser-cutting, waterjet, deburring, bending and more. For machine builders, the Digital Twin concept means there is no need to fabricate a single structure as the entire machine’s functionality and kinematics can be formulated, tested and experienced in real-world conditions — all in a virtual environment. This Siemens development greatly reduces the design, commissioning and training time as a machine builder’s customer can use the machine in simulated production prior to its build phase. This concept applies equally to automation hardware such as robotics. Sinumerik Run MyRobot runs as a direct control of the machine through the Sinumerik CNC onboard — eliminating the need for a second controller as
the robot program functions through the second channel on the CNC. Higher efficiencies are achieved along with reduced hardware plus setup, training and maintenance time-savings. For both the machine builder and end-user, the additional benefits of a smaller footprint and greater cell productivity are realized. Lastly, Siemens offers its end-to-end solutions for additive manufacturing. Working together with several machine builders, Siemens is already involved in the motion control of this emerging manufacturing segment. Siemens Messaging Experts (SMEs) in the areas of digitalization, additive manufacturing, robotics, CNC automation, drives and motors are available to discuss the full range of manufacturing solutions with machine builders and end-users in the fabrication industry.
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IMD | 25
Workforce Development
Why You Must Be A Trusted Advisor To Candidates Too By Jeremy Eskenazi, SHRM-SCP
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recruiter at a company is tasked with getting the best talent from the market at the best price for the company. This was a very common understanding of what recruiting was at its most basic level for a very long time. While the first part still holds, everyone can probably agree that times have changed, drastically. Recruiters must be a trusted advisor to the business – this continues to be a staple of good consultative recruiting. Now add the notion that ‘us and them’ is now the worst approach you can use if you want to get the best talent to join your team and accept your offer. While you’ll continue to build relationships with hiring managers and internal stakeholders – you can no longer treat the candidate as anything less. In a competitive market, you must also be a trusted advisor to candidates. You may be wondering how you can advocate for both sides – isn’t that usually why everyone gets their own lawyer in a battle? In recruiting, it doesn’t have to be that extreme
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and you truly can negotiate and bargain in good faith for both parties. If you’re not quite convinced yet, here are three really important reasons to consider: 1. In a competitive market, you will lose if you’re not seen to be helping the candidate as well. Many organizations are moving to transparent salary ranges, flexible and customized perks, and understanding what candidates want and need on an individual level. Gone are the days you can throw out the lowest offer in the salary range and expect your candidate to be waiting by their phone ready to accept. Instead, you’re likely one of several offers they will get, and you’ll be the one hopefully to get a call back with positive news. Don’t get left behind companies putting out their best offer after asking candidates exactly what they want! 2. How you make people feel matters – in a candidate driven market where there is a labor shortage, you cannot be remembered as the organization who jerked
IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
people around, kept them hanging, lowballed them, or anything near that experience. Other companies will move faster, remove barriers, skip interviews and archaic outdated testing practices in favor of hiring for attitude, potential, and a growth mindset. Some organizations are moving to offer same day and offering positive coaching and feedback through the process. This smooth process, transparency, speed, and the lack of hoops to jump through will not only leave a slower company with a mediocre offer in the dust, but if the candidate does take time to compare multiple offers, how they were treated throughout the process will weigh heavily. It’s a reflection of how a company treats their people and when you have options, culture can often be the tie breaker. Don’t lose on this front because you don’t care about the candidate experience. 3. Money doesn’t win every time – you help them win. One of the most important jobs a recruiter has is listening and understanding what the hiring manager is looking for, but equally important, what will it take for the candidate to accept your offer. Passive candidates who are top performers will not leave their current company without a compelling offer and they are likely to receive a counteroffer to stay. If you’ve been listening to the candidate and building rapport, you might think that they only took your call because they want more
flexibility in their schedule. If you offer a lot of cash, but no flexibility, do not be shocked when they turn down your 30% pay bump in favor of a four-day work week at their current employer. It’s critical to learn who candidates are and what motivates them – and help get them a package that is coveted. Candidates will only consider your company if you can offer them something compelling. This is true at all levels of organizations and across all job functions. In the long era ahead with predicted labor shortages, you’ll need to compete on a variety of fronts. Treating candidates as if they are one of many and they should be lucky to hear from you when you’re ready, will no longer fly. Many candidates these days have multiple options, and your top talent who you thought were happy are suddenly resigning before you can blink. It’s difficult to recruit because there are so many relationships to manage, and it can be emotional at times. Use that emotion and that human connection to your advantage – help get your candidates what they really desire. That $10K that you absolutely didn’t think you could negotiate for might actually be much less valuable to them versus time and course fees for a certification they want. The overall cost might be half but showing an interest in what they desire and making it happen matters greatly. When was the last time you asked a passive candidate who would be perfect for a role at your company what it
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IMD | 27
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ACTEK would take for them to consider making a move? How many times did you actually try to make it happen for them before you got an offer? Did you think about what they asked for after they ghosted you and wonder why you didn’t just push for them? It’s not always going to work out perfectly – some candidates surely push the boundaries when they know they are the right fit for the role. If their ask is reasonable, it probably means there is a glimmer of interest in what you can offer them, and you might have a shot at bringing some amazing talent into your team (the best feeling in the world for recruiting professionals – right!?!). In today’s marketplace – you'll lose candidates if you don’t advocate for them. Help any way you can – if that means coaching them on how to ask for more money, time off, paid benefits, development investment, etc. Help them prepare for a potential counteroffer so they feel comfortable saying no to it or showing them financial projections that help build your case. There is so much you can do to show that while you work for a company, you are also on their side. Earning candidate trust and showing you can advocate and advise them too is a competitive edge you will desperately need – consider how you’re doing at it today and the potential you have to do better.
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New Technology
Mobile Robotic Equipment Boosts AMR Performance at TE Connectivity
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E Connectivity successfully deployed mobile robotic equipment (MRE) from ROEQ on autonomous mobile robots (AMRs) from MIR to address labor shortages and inefficiencies at its manufacturing plant in Esztergom, Hungary. The easy-to-use system handles material handling applications and has resulted in a productivity boost and plans to deploy additional ROEQ solutions. TE Connectivity, a Tier2 supplier to global automotive supply chains, is a subsidiary of US-based TE Connectivity, which serves a wide variety of segments within the electronics industry, from aviation and telecommunications through healthcare and smart technologies. It's the company’s Hungarian facility, which employs more than a thousand people, manufactures passive electrical connectors and connector housings using plastic injection moulding. These products are found in the vehicles of leading automakers, including the Volkswagen Group, PSA, and Mercedes.
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AMRs and mobile robotic equipment (MRE) Autonomous mobile robots (AMRs) have revolutionized intralogistics in just a few years, enabling manufacturers to automate the movement of raw materials and finished products efficiently and safely within production facilities. AMRs are easy to program and, when combined with appropriate Mobile Robotic Equipment (MRE) such as top rollers and top modules, are versatile enough to handle a wide range of applications. MRE enables companies with intralogistics requirements, like TE Connectivity, to fully harness the capabilities of their AMR. MRE can be connected to an AMR using simple and secure mechanisms, expanding the possibilities of the deployment. Examples of MRE include top roller modules for transferring materials, carts and lifters used to transport crates, bins, packages, and pallets. Using AMRs and appropriate MRE, robots can move up to a ton of goods or create a conveyor logistics system that communicates directly with automated production lines.
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Additionally, AMRs can be used in virtually any industry with goods and material transport requirements.
Challenges in internal logistics Back in 2019, TE’s Hungarian plant was experiencing problems in material handling due to the inefficiency of their existing material handling systems, which had reached the limit of its capabilities. The situation was made worse by labour shortages, as interest in low skilled warehouse operator positions declined sharply. Industry 4.0-driven transformation is part of TE’s corporate goals, so the company made the decision to automate internal logistics using AMRs. In order to replace the plant’s material handling system, the company’s employees began to assess the opportunities available on the market. They needed a flexible system that was simple to alter and extend, but at the same time easy to operate. Safety was also an important consideration because of the narrow traffic routes in the plant, frequent changes in internal layout and tasks, and the continuous movement of raw materials, finished products, and people on the factory floor.
simultaneously. Several AMR and MRE solutions were tried, with the company concluding that the MiR200 AMR combined with a TMC300 top module, cart and docking station from MRE specialists ROEQ, were best suited to its needs. “Our fleet consists of six MiR200s, most of which carry raw materials and finished products between the warehouse and one of the value streams. What we have is a semi-automatic plant, as missions are launched by the employees who also have to move the carts connected to the robots both in the production area and in the warehouse. Therefore, simple docking and ease of use were placed high among our expectations regarding the modules,” explains Gábor Miszler, Continuous Improvement Analyst at TE. The ROEQ TMC300 top module, with ROEQ cart and docking station, provided TE with a standardized solution that was made extremely easy to integrate and deploy since both the top module itself and the accompanying ROEQ Assist software are fully compatible with MIR robots. “This is precision technology, it was obvious from the first glance that it has been developed specifically for these devices, and this comes with many benefits,” said Miszler.
Looking for the best To determine the best AMR for its needs, TE effectively turned its Hungarian plant into an industrial test environment, experimenting with multiple parallel solutions
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IMD | 31
the missions do not have to learn how to operate two types of programs. And on top of that, regularly occurring tasks can be pre-programmed, which means that missions can be launched quickly and easily, without any special expertise. Both capabilities were a major advantage when the technology was introduced. Employees were initially strongly averse to robots. It took a lot of effort to have them accept the technology and understand that it can really make their job easier. It was an important milestone when two warehouse workers per shift learned how to operate the robots at a basic level and how to correct simple errors, such as being stuck or getting lost. As workers became active users and were exposed to the ease of use of both the MiR 200 and ROEQ’s Assist software, their perspectives changed, which was a major factor in the successful deployment. The patented locking mechanism of the carts allows precise and safe connection to both the robot and the docking station. Whilst the ROEQ Assist software provides continuous tracking: one can check at any time which robot or dock a given car is connected to. At the endpoints of the missions – in the production area and in the warehouse – the staff can easily disconnect the carts from the robots and then move them manually. TE’s experience shows that ROEQ carts are remarkably stable and safe. The robots have a proud zero accident-zero property loss record in the two years since they were deployed. Moreover, Tyco found that the ROEQ cart solution can increase the payload of AMRs, which improves the overall efficiency and throughput of the material handling process.
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Strength in harmony “Tyco purchased ROEQ’s modules and carts after the outbreak of the Covid19 epidemic. Due to travel restrictions engineers from the Danish plant were unable to travel to Esztergom to assist in the deployment. However, thanks to easy implementation, detailed manuals and remote support from the manufacturer and the distributor, we were able to set up and coordinate the devices and the programs ourselves,” says Gábor Schvamberger, Logistics Analyst at TE. ROEQ top modules and equipment are extremely reliable and ROEQ is quick to support users in the unlikely event any repair or maintenance is required. “However when we encountered a challenge during the first period, the distributor and ROEQ engineers provided immediate assistance. They discovered the cause and came up with a technical solution that was able to permanently eliminate the phenomenon”, explains Schvamberger. ROEQ partner in Hungary, VFP Systems, supported TE during the acquisition of robotic solutions. According to András Dobner, Head of Internal Logistics at the company, the multifaceted capabilities of AMRs can only be fully realized when paired with the appropriate MRE: “A huge competitive advantage of ROEQ standardized solutions is that both the hardware and the software fit seamlessly with MiR robots. Thanks to the unity-oriented design, the implementation of the system went very smoothly despite the circumstances, and it has been operating with a high level of reliability ever since. The safety features
integrated into ROEQ products also enrich the robots navigating between people in the production area with valuable added skills.”
The future belongs to the robots The TE Esztergom plant currently uses 3 ROEQ TMC300 top modules, 15 ROEQ 300E Easy-Pull-Out carts and 10 easy locking docking stations for material handling tasks. The company is currently building a new production hall optimized for the characteristics of AMRs with the goal of leveraging its AMR fleet’s capabilities even more effectively and increasing AMR utilization by procuring the right modules. The experience so far has been extremely positive. MiR AMRs equipped with ROEQ top modules and equipment dramatically accelerated the pace of internal logistics, and all this is accompanied by favourable return rates. It is estimated that only half of the average payback time in logistics is required, as the payback time for this automation investment is around 2-3 years – despite experimenting with several tools during the automation project before finding the ideal solution. ABOUT TE CONNECTIVITY TE Connectivity empowers engineers by designing and manufacturing sensor and connectivity products for a safer, sustainable, productive, and connected world. As the go-to
engineering partner for today's innovation leaders and technology entrepreneurs, we are helping solve tomorrow's toughest challenges. Our electrical and electronic products are engineered to reliably connect and protect the flow of data, power, and signal – in electric vehicles and aircraft, digital factories and smart homes, and life-saving medical devices, efficient utility networks, and the global communications infrastructure. For nearly 80 years, our focus on engineering for reliability and empowering the potential of people has helped drive innovation in technology transforming how the world lives, works, and connects.
ABOUT ROEQ ROEQ develops equipment for mobile robots that effectively bridges the gap between the warehouse and production, allowing the industry to achieve fully automated internal logistics between storage and production. ROEQ was founded in 2017 and is a 100% Danish-owned company with the majority of the robotic components also supplied by Danish companies. Today, ROEQ develops, manufactures and sells its products in nearly 40 countries through more than 100 distributors. ROEQ's range of top modules, cart, rack and lifter and roller solutions makes it possible for a MiR robot to pick up/drop off carts or pallets with items on e.g. a conveyor belt with no human involvement. ROEQ's equipment is used in the industrial and logistics sector, as well as the healthcare sector. For more information visit www.roeq.dk
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Process
Compact printed circuit heat exchangers (PCHE), produced through a diffusion bonding process, surpass traditional alternatives in extreme temperature and pressure environments.
Diffusion Bonded Printed Circuit Heat Exchangers for Severe Environments Compact printed circuit heat exchangers (PCHE), produced through a diffusion bonding process, surpass traditional alternatives in extreme temperature and pressure environments
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raditional plate or shell and tube heat exchangers have long been used in processing industries. Today, however, with many new applications involving high pressures, temperatures, and exposure to corrosive environments, more manufacturers are turning to compact printed circuit heat exchangers (PCHEs). A PCHE is a multi-layer heat exchanger consisting of thin, flat metal plates into which fluid flow microchannels are chemically etched in each layer to form a complex flow pattern. The layers are then diffusion bonded together to create a dense heat exchanger with superior airflow and heat transfer properties. When designed this way, a heat exchanger can be up to 85% smaller and lighter than traditional plate or shell and
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tube designs. In addition, PCHEs do not require excessive pipework, frames, or other associated structural elements, further reducing costs. “A high-quality diffusion bonded PCHE can withstand very high pressures of hundreds of bars and extreme temperatures beyond 800°C. As a result, PCHEs are well suited for a wide range of demanding applications, including oil and gas, hydrogen vehicle fueling stations, and aerospace,” says Dr. Udo Broich, Managing Director of PVA Industrial Vacuum Systems GmbH, Wettenberg, Germany. Dr. Broich, who wrote his doctorate thesis on joining technology, has focused on vacuum brazing and diffusion bonding for 25 years. PVA TePla AG is a global manufacturer of industrial furnaces and PulsPlasma nitriding systems.
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Diffusion bonding versus brazing For many years, diffusion bonding has been utilized to join high strength and refractory metals that are either difficult or impossible by other means. The process involves applying high temperature and pressure to the bonding part in a high vacuum hot press like those offered by PVA TePla; this causes the atoms on solid metallic surfaces to intersperse and join. The final piece will have little or no interface lines or striations if the materials are similar; the interface of one material blends into the other, and vice versa. The same result can also be achieved with dissimilar materials with the right equipment, material preparation, and process. The key to the process is utilizing diffusion bonding to join the layers over other alternatives, such as vacuum brazing. Although brazing is widely used for joining metals under normal conditions, it can be insufficient in high temperature, pressure, or corrosion situations. Brazing is a joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint. The filler metal flows into the gap between the layers through capillary action. With a proper choice of filler material and process parameters, brazing can also create high strengths and thermal resistant joints. However, as the filler metal always has a different chemical composition from the bonding part materials, the properties of brazed
components usually cannot reach that of a solid part., according to Dr. Broich. “In the case of brazing a PCHE, engineers must consider another issue: during brazing, molten filler metal can penetrate the microchannels and solidify, blocking the channels required for airflow. This can render the PCHE quite ineffective,” says Dr. Broich. “Since diffusion bonding requires no filler metal and is a solid-state joining process, the microchannels remain intact.” “When the layers of a PCHE are diffusion bonded, the final product retains the parent material's mechanical, chemical, and thermal properties. Given the high strength and integrity of the material, PCHEs can withstand very severe operational conditions,” explains Dr. Broich. A significant advantage of diffusion bonded PCHEs is that it significantly reduces the size of the heat exchanger. “PCHEs have about 85% less mass and volume than traditional heat exchangers, while the microchannels provide a large surface area for heat exchange,” says Dr. Broich. “Achieving the same heat transfer rate with a standard [plate, or shell and tube] heat exchanger] design requires much more mass and volume.”
Growing Markets for Diffusion Bonded PCHEs Due to the inherent advantages of diffusion bonded PCHEs, many industries are adopting this evolving technology to improve heat transfer in various applications.
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Oil and Gas The compact, efficient heat transfer capabilities of PCHEs are ideal for many oil and gas applications, including preheaters, superheaters, gas compression coolers, high-temperature recuperators, and liquified natural gas (LNG) exchangers. For example, in offshore LNG production, natural gas is converted to a liquid for safe transport or storage when pipelines are not available. LNG takes up only a fraction of the space in its liquid form, but the natural gas must be cooled to approximately -260°F as part of the process, generating heat. A PCHE is a practical, compact solution for small footprint areas like onboard ships.
Hydrogen Fueling Stations PCHEs are a requirement in hydrogen vehicle fueling stations. Stored hydrogen must be pre-cooled to approximately -40°C before being transferred into the vehicle's tank. This cooling process prevents potential damage from the excessive temperature that can damage tanks during filling. “To fill a tank, pressurized hydrogen is dispensed at roughly 1,000 bars; this process generates excessive heat,” says Dr. Broich. “Because it is critical that the temperature not exceed the critical limits of the tank, hydrogen is pre-cooled to about -40°C. The PCHE in the fueling station’s cooling loop must withstand 1,000 or more bars of pressure and temperatures as low as -50°C. The compact design of PCHEs also eases integration with the hydrogen dispenser casing.”
Aluminum Heat Sink Applications: Electric Vehicle and Aerospace Aluminum heat sinks are popular for the thermal management of many critical devices where weight is a factor, including automotive and aerospace. Aluminum heat sinks are also commonly used with electric batteries. The most common aluminum alloys used in heat sinks and exchangers are the 6000 series alloys. However, magnesium and silicon are the primary alloying elements and are difficult to join with methods such as brazing. “In many heat sink applications, brazing flux is often prohibited. Therefore, vacuum brazing remains a joining technology using filler metals based on an aluminum-silicon eutectic alloy. However, these alloys have a melting point of 580°C, very close to the melting point of the base material, thus providing only a tiny process window to achieve high-quality bonds,” says Dr. Broich. He notes that PVA TePla has developed a diffusion bonding process to successfully join high alloyed aluminum materials like 6061 over the years.
Optimizing Furnace Design for Diffusion Bonding There are various approaches to furnace design and process implementation for diffusion bonding of PCHEs. Advances in high vacuum furnace hot presses allow superior pressure control and rapid cooling systems
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that improve bonding, increase yields, and significantly decrease cycle time. Manufacturers such as PVA TePla offer multi-cylinder systems with large pressing plates that accommodate various parts. The largest, the company’s MOV 843 HP, can process substrates as large as 950mm (37.4”) x 1300mm (51.18”), which is quite a large area for diffusion bonding. The pressing force is 8,000 kN. Research is underway to increase this geometrical limitation as well. The integrated press provides remarkably consistent pressure across the entire surface by controlling and synchronizing each cylinder. The MOV also comes with built-in pressure transducers along the bottom of the pressing plate. The individual hydraulic cylinders can be adjusted in the software to achieve uniformity even over large areas based on sensor feedback. Dr. Broich points out that high-bonding strength is critical for applications involving PCHEs in extreme settings. “It requires a high-strength design [when a high vacuum hot press is needed] of the pressing unit [pressing rams and platens) to transfer 800 or 1000 tons at 1,000°C or even higher temperatures,” says Dr. Broich. In addition, the pressing unit should have a design that minimizes the mass within the hot zone while achieving uniform force distribution throughout the working space and pressing plate, according to Dr. Broich. “The design of a diffusion bonding machine should enable the shortest cycle times possible while saving energy by reducing its thermal mass; this is very important to productivity and cost-effectiveness,” he points out. To produce a high-quality diffusion bonded PCHE, working with an expert partner like PVA TePla can be essential for manufacturers that require process and technology support. “Most of our customers are not familiar with this technology. We support them with basic process technical knowledge so they can correctly use the machine to produce a high-quality diffusion bonded PCHE,” says Dr. Broich. Due to the rapidly expanding need for this precision technology in the U.S., PVA TePla is opening a diffusion bonding technology center in Corona, California. This summer, a full-scale industrial furnace that matches the capabilities offered in Germany will be available. PVA TePla will be able to demonstrate the machine's bonding capabilities, run R&D samples, and provide processing services. “In both the U.S. and Germany, we can demonstrate the quality of the bonds before a customer decides to invest in a machine. We handle most of the elements of process development to prove the technology and assist in scaling up to production volumes. Alternatively, we can provide full-scale contract processing for customers if they outsource production,” says Dr. Broich. For more information, contact PVA TePla America at 951-371-2500 or 800-527-5667 or visit www.pvateplaamerica.com.
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Industry Insight
The Robotic Edge: Workflow Optimization for Market Advantage
By: Chris Caldwell, Product Manager at Yaskawa America Inc. – Motoman Robotics Division
T
he impact of Industry 4.0 and its adjacent technologies continues to permeate industrial processes, creating a new world of opportunities for product and service transformation. A key driver of this is the successful integration, synchronization and monitoring of highly efficient robots within current production networks. Advances in artificial intelligence (AI), simulation and modular hardware provide even greater capability and accuracy, opening the door to the Internet of Robotic Things (IoRT) – where robot information and other device data are combined in real time to calculate alternative courses of action for objects in the physical world. Streamlining processes and optimizing capacity at this scale can only happen, however, if robots are leveraged in the first place.
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Robotic Workflow Preparation Whether a new user is wanting to implement a more efficient production path from end-to-end or a manufacturer is looking to refine an operational bottleneck by adding capacity to current automation, the use of flexible robots with intuitive software platforms can deliver a variety of productivity gains. From faster cycle times for increased production throughput to reduced part rework for improved product quality, the meticulous planning for robotic automation is key to transformative success. Consider the following:
Understand Current Processes While this concept may seem straightforward, a lot of thought should go into it. First, it is important to have a clear
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understanding about how much robot implementation is required. Will automation be utilized end-to-end, integrated for a single step or somewhere in between? If for a single- or multi-step process, know the main reason(s) for robot usage. If the task at hand is dull, dirty, dangerous or difficult, it is most likely an ideal candidate for a highly flexible robot that can be added to a current workcell or production space. Next, consider how parts are transferred. How controlled are infeeds and outfeeds? While random configurations can be automated, this typically adds more complexity to the system design and may incur additional cost. Therefore, knowing your overall budget and keeping a target payback period in mind will help guide the solution selection process. With these selections in mind, have an idea of how “smart” the system needs to be. Is new ground being broken with the task at hand that may require the use of cutting-edge technology? Or, are there proven examples of automation similar to what is needed? Doing a little bit of research can go a long way to guiding the system design conversation with a robot supplier or integrator. From stationary systems for machine tending to mobile platforms for warehouse picking, and everything in between, a range of solutions exists to optimize operations. Keep in mind, if a current production layout uses more fixed or hard automation, the less complicated it should be to implement robots. If more inputs or human-robot interaction are required, integration is typically more difficult. Other concepts such as tooling and safety guarding should also be weighed.
Outline Key Objectives Before adding robots (or any piece of capital equipment for that matter) to a process, it can be helpful to understand the “why” behind the need. Does the motivation come from labor shortages, production spikes, quality concerns or capacity issues? This often helps determine the use of a slower yet perfect system versus a faster system with limitations. Along the same lines, how will short-term or long-term success be measured? What key performance indicators are important? For this reason, a solid grasp for concepts like target cycles per minute/day/hour and acceptable failures per hour/day/minute are advised. A clear picture of the ultimate end goal is always helpful. Whether it is to gain competitive advantage, raise additional revenue, bolster employee morale or a mix of reasons, knowing the expected outcome helps drive the project from start to finish.
Garner Employee Support In conjunction with knowing the required objectives, having a team of motivated individuals aligned with the plan and willing to embrace robotic automation is highly suggested. In fact, helping current employees see the quality of life benefits and job advancement opportunities that robots bring to the table is a great way to garner the human resources needed to make implementation happen. Some companies may choose to appoint, or even hire, a “workcell champion” – an employee fully dedicated and accountable for integration, programming, utilization and maintenance of the robot system. This valuable team member can be instrumental and help garner support from other stakeholders for managing deliverables and meeting deadlines.
Borrow Automation Brilliance In most instances past performance is the best predictor of future success. This is why most companies partner with an experienced robot supplier or integrator, rather than reinventing the wheel. This also saves on effort, time and resources. When choosing the ideal robot advisor, evaluate their technical prowess and ask about the technical feasibility of the project at hand. If this cannot be properly addressed, finding another option may be in order. For those still on the fence about robotic automation, attending regional tradeshows, reading industry publications and visiting automated factories can provide key insights for how to add robots to certain processes.
Popular Robot Additions While adding robots to current production can range in application depending on industry and process requirements, several tasks that are commonly aided by robotic automation include: INDUSTRIAL MACHINERY DIGEST.COM
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3D Printing To reduce lead times, many fabricators are turning to 3D printed parts made on site. Just as next generation 3D printers with advanced servo technology offer advanced motion control over stepper motors, robots are also transforming additive applications. Their excellent path performance, rigid mechanical structure and high dust protection (IP) ratings – combined with advanced anti-vibration control and multi-axis capability – make select six-axis robots an ideal choice. Not only can highly flexible robots perform key actions for subtractive manufacturing and hybrid additive/ subtractive methods, they are also well-equipped for complimentary 3D printing tasks. Whether handling printed parts in multi-machine installations, assisting with powder management or completing part finishing tasks like grinding, polishing, deburring or cutting, robots are ideal for front-end production tasks related to part fabrication.
Machine Tending As mentioned, robust robots are well-suited for tending operations. Frequently chosen for the robust ROI they can bring, modern day press transfer robots and control
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systems are used to optimize throughput, increase safety and maximize profit. Whether making agricultural, appliance or automotive components, and regardless of size or style (hydraulic or servo driven) of the press, heavy payload robots with heavy-duty drive systems and high vibration ratings help smooth the way for this highly demanding, repetitive task. Another trending task frequently automated is the removal of parts from horizontal injection molding machines (IMMs). Streamlining the process even further, especially for small- to medium-sized parts, are easy-to-use electrical interfaces that maximize uptime and throughput.
Logistics Tasks A growing number of advanced technologies are making it easier to configure, program and integrate robotic solutions for high-volume backbreaking tasks. This is particularly true for parcel sortation, piece-picking, case packing and palletizing. Feature-rich vision systems are being added to existing lines to help feed incoming parts or products, and are helping to instruct industrial and collaborative robots alike on how to manipulate each item. Strides in AI are also making this area a new possibility for automation despite the complex variety and shape.
Other unique tools for dynamic factory and distribution environments, such as highly adaptable autonomous mobile robots (AMRs) equipped with LiDAR sensors, are also meeting various production needs. These robotic platforms – equipped with robots, vision systems and custom end-of-arm tooling (EOAT) and more – autonomously maneuver with great ease and safety through a facility to perform assigned tasks like picking, sorting and on-demand material transport.
Dispensing Applications Manufacturers that address existing coating, dispensing or painting issues via robotic automation often see tangible results. Consistent finishes, greater system uptime, reduced material waste and increased worker safety are common benefits. High-performance models with hollow-wrist designs and wide wrist motion ranges can accommodate large or complex shapes, while more scalable systems are optimized to execute the painting of smaller components.
Welding Workcells Modernizing a current welding workstation via a single robot arm (or more) can be very effective at optimizing floorspace and increasing throughput. For example, if a manufacturer has a single robot workcell with a cycle time of ten minutes, adding a second robot can reduce the cycle time per part in half, while not increasing the footprint of the workcell.
Six-axis collaborative robots with built-in safety-rated Power and Force Limiting (PFL), can easily supplement manual welding or be rolled-up to large, heavy workpieces in a factory setting. Not only does this provide the weld capacity needed for smaller operations, but also, it maximizes floorspace in tight environments.
Continuous Improvement Mindset The rapid pace of technological change is leveling the playing field for production operations. Companies that were once relegated to only automating “low-hanging fruit” are now able to integrate robots for more complex tasks. For many, this post-install optimization is more rewarding than the initial system, as it sets the company up for even greater operational control and efficiency. The more devices on the factory floor, the more data that can be captured via networked production environments through user-friendly device management platforms. This provides the ability for data-driven optimized planning for preventative and predictive maintenance. Innovative software tools, like Yaskawa Cockpit™ – an edge server solution, use a leading OPC-UA to provide comprehensive insights that help decision makers gain a competitive edge. Moving forward, companies that integrate new methods and technologies, including robots, will have greater capacity to scale operations for meeting missioncritical business goals.
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Product Showcase
PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers. Cracking the Code: Connecting IMD Readers with More Information To learn more about each product, scan the included Quick Response (QR) code with your mobile device. These special barcodes have been designed to allow our readers to quickly and easily discover more information available on IndustrialMachineryDigest.com. WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com
Siemens adds intelligence-based design to Xcelerator portfolio with latest release of NX Siemens Digital Industries Software today launches the latest release of its industry leading NX™ software, part of the Xcelerator portfolio of software and services. The latest release of NX software leverages advanced technologies, such as artificial intelligence (AI) and advanced simulation capabilities, while continuing to invest in significant productivity and capability enhancements to enable its community of designers, engineers and manufacturers to innovate more quickly. “In the latest revision of NX, Siemens Digital Industries Software has smoothly woven topology optimization design from requirements, through to component generation, additive manufacturing, and final machining by leveraging their convergent modeling and automated model-based definition authoring for PMI generation together with task-based collaboration." said Dr. Ken…
AAT3C Announces New Metrology, Quality Control and Adaptive Manufacturing Software Contract AAT3D was successful in securing a major software contract that will integrate CAPPSNC™ software to directly interface with controllers on large CNC machines to provide dimensional metrology…
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Coxreels Improved Options for the Vacuum Series Reel Coxreels V-100 Series product line has been improved and expanded! Introducing the new 1 ¼” vacuum hose reel V-112-735 without hose and the V-112H-735 with hose. The new model is a smaller frame size featuring 12” diameter discs instead of the original 17” diameter discs and…
Whether it’s a stand-up or sit-down application, this Creform workstation helps provide for an optimum assembly operation. Creform Corporation, a manufacturer of unique products for the design and building of material handling structures and automated guided vehicles has developed an assembly…
IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
DESTACO Adds To Its Heavy-Duty Manual Clamp Product Line
EXAIR.com Improves Web Accessibility with ADA Compliance Features
DESTACO is pleased to announce that it has added two new models to its heavy-duty Manual Clamp product line. The 503-MLBR and 533-LBR models are extensions of DESTACO’s 503-MLB and 533-LB vertical toggle-lock clamps with the new…
EXAIR.com has added improved web accessibility for people who are affected by a variety of impairments. By addressing these impairments with specific tools, the EXAIR. com website has become the first in the industry to provide ADA compliant…
Want quiet? Go nano. Gear Inspection at Nano Level @Control 2022
PlantMonitor from HEIDENHAIN to Aid Digital Manufacturing
New Jorgensen FlexFiltration Line Delivers Simplicity and Value
With its brand-new 300GMS nano Gear Metrology Center, Gleason presents a world- first at Control Show 2022, May 03-06, Stuttgart, Germany. The capability of measuring gears at sub-micron level, executing advanced waviness analysis and…
HEIDENHAIN’s new PlantMonitor is a digital solution to aid the manufacturing shop floor. Now available for companies interested in simultaneously monitoring and analyzing production data at multiple sites utilizing machine tools…
Jorgensen Conveyor and Filtration Solutions has introduced its new FlexFiltration line that also includes the company’s new Flex G Series of modular filtration systems. The new cost-effective systems feature pre-engineered modules…
Industrial Automation Partner Gibson Engineering Bolsters Kassow Robots’ Position in US Manufacturing
Join the machine shop revolution with KBC Tools & Machinery and Evolution!
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Kassow Robots, a developer of 7-axis cobot solutions for machine tending, material handling, and related applications, has partnered with Gibson Engineering (Norwood, Massachusetts, USA)…
KBC Tools & Machinery is pleased to announce that it is now carrying and stocking the Evolution line of heavy duty Metal Cutting Power Tools made especially for metalworking in both Canada and The US and featuring chop saws. Now you can cut through…
KUKA Showcases Complete, End-to-End Automation Solutions and Advanced Vision Capabilities at Automate 2022 At Automate 2022, attendees will have the opportunity to experience how complete, end-to-end automation solutions from KUKA Robotics can help them exceed their production goals. In booth #1823…
Coordinate measuring machine (CMM) manufacturer LK Metrology has introduced a third release of its CAMIO 2021 programming and measurement software featuring numerous improvements. The most significant is the inclusion of a module that automates the inspection… INDUSTRIAL MACHINERY DIGEST.COM
IMD | 43
ModuleWorks Releases 2022.04 Digital Manufacturing Software ModuleWorks announces the release of its 2022.04 CAD/CAM software components for digital manufacturing. This is the first major ModuleWorks release of 2022 and contains new and enhanced features across the entire product range…
Purdue-related startup Araqev creates qualitycontrol software for additive manufacturing, 3D printing processes
Siemens’ SynthAI revolutionizes machine vision training with artificial intelligence
Aerospace, automotive, consumer products, medical devices, national defense and other sectors that use additive manufacturing and 3D printing technologies…
Siemens Digital Industries Software’s SynthAI™ service is delivering the power of machine learning and artificial intelligence to solve the challenge of training machine vision systems.“We were looking for a quick…
SINAMICS S120 drive system — firmware and hardware updates increase user-friendliness
Weiler Abrasives Introduces Full Offering of Foundry Abrasives to Improve Safety, Productivity
New cermet turning insert from Walter can double tool life and ensures maximum dimensional accuracy
Siemens is offering new features in hardware and firmware for its SINAMICS S120 drive system. Operation is much easier in firmware V5.2 through the integration of a web-server. The webserver has a new…
Weiler Abrasives, a leading provider of abrasives, power brushes and maintenance products for surface conditioning, announced the availability of its Tiger® abrasives line designed to deliver maximum…
Walter has introduced a new cermet turning insert that deliver superior surface finish with reduced vibration. The new PVD coated cermet grade WEP10C, along with low cutting pressure from its negative clearance…
The new SINUMERIK CNC becomes part of the Siemens TIA Portal
New MESA Model: A Framework for Smarter Manufacturing
Rockwell Automation Introduces New On-Machine Drives
The new generation of machine tool control, SINUMERIK ONE, is at the heart of the digital transformation of CNC machines. As a digital native control, SINUMERIK ONE features not only a new hardware platform, but also versatile software…
MESA International announces the release of a new MESA Model: A Framework for Smarter Manufacturing. The new model intends to help define the current and future landscape of “smart” manufacturing and production. It considers…
Rockwell Automation, Inc. (NYSE: ROK), the world’s largest company dedicated to industrial automation and digital transformation, today announced the release of its new Allen-Bradley Armor PowerFlex AC variable frequency…
44 | IMD
MAY 2022
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MAY 2022
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50 | IMD
MAY 2022
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