Industrial Machinery Digest - July 2022 by Industrial Machinery Digest

IndustrialMachineryDigest.com | July 2022

North America’s Manufacturing Resource for Industry Professionals Since 1986

» What is the Future of U.S. Manufacturing? » Industrial Production: Eliminate Indoor Airborne Contaminants to Protect Worker Safety, Productivity » Global Equipment Manufacturers Serve Life Sciences and Biotechnology Companies on Cloud ERP » Aerospace and Defense Manufacturers Must Prepare for the Robot Revolution » Automated Storage and Retrieval System Elevates Cobot Productivity » The Great I/O Migration

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Table of Contents

COLUMNS

BUSINESS 4.0 What is the Future of U.S. Manufacturing? By: NRTC Automation

TALKING SHOP Abe Eshkenazi CEO, Association for Supply Chain Management

18 22

FEATURES

NEW TECH Aerospace and Defense Manufacturers Must Prepare for the Robot Revolution Like all manufacturers, aerospace and defense firms must engineer existing or new facilities in preparation for much higher levels of robotic automation. To do otherwise places them at a competitive disadvantage. By Josh Tuttle

Automated Storage and Retrieval System Elevates Cobot Productivity By PBC Linear

By: Del Williams

MANUFACTURING SHOWCASE Global Equipment Manufacturers Serve Life Sciences and Biotechnology Companies on Cloud ERP By Hamilton Company

SAFETY & MAINTENANCE Industrial Production: Eliminate Indoor Airborne Contaminants to Protect Worker Safety, Productivity

PROCESS

DEPARTMENTS

6 8 40 42 46

EDITORIAL DIRECTIONS

49 50

CLASSIFIEDS

INDUSTRY NEWS ON EXHIBIT – IMTS PRODUCT SHOWCASE SURPLUS BUYING & SELLING

ADVERTISER INDEX

The Great I/O Migration Planning an effective, efficient I/O upgrade means partnering with automation experts

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INDUSTRY INSIGHTS Precision Aerospace Machine Shops Leverage Adaptability and Nimbleness to Respond to Complex Machining Challenges JULY 2022

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Editorial Directions I injured my spine in a fall last year. My dog has a tendency to dart unexpectedly toward whatever interests him, and I wasn’t prepared for the sudden change of course. A fractured vertebra kept me flat on my back for more than six months. Bad dog! Anyway, everything changed in an instant. I couldn’t walk, even standing was painful, and sitting in my chair in front of the computer was agony within a couple of minutes. Going to see specialists required hours of preparation, between taking a shower and getting dressed, and I had to use a wheelchair to navigate the vast medical complexes I visited for tests, X-rays, and to see doctor after doctor. This went on for a year and is still ongoing, even though I’m finally back on my feet again. Most of us are acquainted with someone who requires a wheelchair, or some other type of mobility device, to get around. Many are battling unseen maladies that we know nothing about. During my own experience, I truly came to rely on, and appreciate, the kindness of strangers. My head spins trying to recall how much the smallest acts — opening a door, holding the elevator for me, helping me climb into my car — meant in the moment. It also helped keep my spirits up when I was having a particularly hard day; the simplest gesture took on added meaning when the pain and difficulty of merely getting around was draining my inner resources. Now that I’m on the move again, I don’t want those lessons to fade. You can help someone while at the same time allowing them to retain their dignity, whether it involves friends, coworkers, or complete strangers. I’ve heard it said that none of us know what challenges the people we encounter every day might be facing, so be kind. That’s a powerful truism, and one that I don’t plan to forget.

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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

United Grinding and Titans of CNC to Launch New Grinding Academy

Titans of CNC has four United Grinding machines on its shop floor in Texas: the BLOHM Planomat XT profile grinder, the STUDER favorit and STUDER S41 cylindrical grinding machines, and the Walter Helitronic Vision 400 L tool grinder. These machines will be the first tools used to create content for the Grinding Academy. The Grinding Academy launched in June 2022. To view the Grinding Academy, visit grindingacademy.com. To see the complete lineup of machines and for more information on the United Grinding and Titans of CNC partnership, visit titansforgrinding.com.

United Grinding, a global leader in CNC grinding technology, and TITANS of CNC, a manufacturing group of part-makers, influencers and educators, have collaborated to launch the all-new Grinding Academy. Much like TITANS’ existing machining and aerospace academies, the Grinding Academy will offer free online courses that teach and train the next generation of machinists. “We’re so excited to be teaming with Titans of CNC on their Grinding Academy,” said Paul Kössl, Global Head of Marketing and Business Development at UNITED GRINDING Group. “The precision and quality made possible by CNC grinding is something that more manufacturers should know about. The academy will showcase all of that power and potential, while also teaching viewers how to harness it.” Titans of CNC’s humble origins — a lone machine shop in California — has grown into the world’s first CNC educational platform that’s recognized by engineers, machinists, hobbyists, students and educators around the world. With over a million followers across social media platforms including Facebook, YouTube, LinkedIn, and TikTok, TITANS of CNC has become the trusted voice in manufacturing. “We’re grateful for partners like United Grinding, whose world-class equipment and collaborative philosophies allow us to do what we do, which is educate and inspire anyone who has a passion for manufacturing,” said Titan Gilroy, CEO at TITANS of CNC. “The Grinding Academy will teach students the full spectrum of grinding from fundamentals to finished parts, and the curriculum found at grindingacademy. com will always be 100% free.”

LSU Mechanical Engineering Faculty Team Up with NASA to Advance Additively Manufactured Materials Launch vehicles and propulsion systems are very complex and must survive extreme thermal, dynamic, pressure, and environmental loads. The materials and alloys used in these systems are often challenging to produce, costly, and have long lead times. Thanks to a NASA EPSCoR (Established Program to Stimulate Competitive Research) and Louisiana Board of Regents grant, LSU Mechanical Engineering Professors Shengmin Guo and Michael Khonsari are working with NASA and LaSPACE to advance additively manufactured alloys to help reduce cost and lead times. “Our goal through EPSCoR and other partnerships is to advance technologies, including novel alloys, for our missions and commercial spaceflight partners,” said Paul Gradl, NASA principal engineer at Marshall Space Flight Center in Huntsville, Ala. “Part of our role is to understand the additive manufacturing processes better and provide accessible data so that NASA and industry can make better use of these processes and novel alloys.”

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For the past 18 months, Guo and Khonsari have been experimenting with alloys used in liquid rocket engine components made by additive manufacturing (AM) methods, such as laser powder-bed fusion (L-PBF) and laser powder-directed energy deposition (LP-DED) methods. When NASA makes parts using additive manufacturing, the parts cost 50% less to produce than parts made with traditional manufacturing, and parts can also be produced two to 10 times faster. Traditional parts can take a year to make, whereas, the same part can be made using AM methods in a few weeks, or for the most complex parts, in a few months. L-PBF metallic 3D parts are fabricated by sequentially and selectively melting thin powder layers according to CAD-directed laser scanning strategies. Multiple laser line scans form the desired 2D section shape, followed by multiple powder deposition/laser irradiation cycles that generate complex 3D metal/alloy parts. LP-DED allows for large AM parts to be fabricated with a deposition head attached to a robot based on a CAD-directed toolpath. In this project, Guo, Khonsari, and their graduate students conducted thermal and mechanical property measurements on more than 30 AM alloys and processes and established protocols for sample preparation, thermal and mechanical property testing, material characterization, and data analysis. Supported by EPSCoR and NASA Marshall, this project will provide NASA and industry with detailed

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datasets regarding thermophysical properties of the metallic AM parts. “We have a lot of complex parts that have internal features and channels that were traditionally made from multiple joining operations (welding and brazing) to fabricate a component,” Gradl said. “As additive manufacturing processes and metal alloys mature, we must have good understanding of the properties to design for these additive processes that include mechanical and thermophysical properties.” According to Gradl, the thermophysical properties are a critical element of the design, and NASA required a substantial dataset for materials used in additive manufacturing processes, which is where the EPSCoR grant filled a gap. A key thermophysical property is thermal conductivity, particularly in high-temperature components, such as combustion chambers, where heat transfer is critical for the alloy being used. “This project builds upon the successful results of multiple National Science Foundation grants, Louisiana Board of Regents grants, and LSU’s investments in material and advanced manufacturing research,” Guo said. Apart from thermal property measurements, this team utilized the LSU Center for Rotating Machinery (CeRoM) equipment to perform mechanical testing and provide mechanical property measurements using the LSU Shared instrumentation Facility. CeRoM houses state-of-the-art

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fatigue-testing equipment, including rotating bending, fully-reversed bending, torsion bending, and tension compression combined with torsion testing apparatuses. “EPSCoR is excited to be associated with this research,” said Jeppie Compton, NASA EPSCoR project manager. “What is lab research today will one day be normal business, and with this database of properties that the team did methodical studies on, NASA and our industry partners could have a huge advantage for decades to come.” Guo’s AM alloy thermophysical property work will also be featured in the appendix of a textbook led by NASA titled “Metal Additive Manufacturing for Propulsion Applications.” This book will be published by American Institute of Aeronautics and Astronautics (AIAA) under the Progress in Astronautics and Aeronautics series.

Agile Space Industries Announces Tom Rubin, Former Microsoft Chief IP Strategy Counsel and Assistant U.S. Attorney, Has Joined Board of Directors Agile Space Industries, the aerospace propulsion experts trusted by NASA, the Department of Defense and defense contractors for over a decade, announced today that former Microsoft Chief Intellectual Property Strategy Counsel and Assistant U.S. Attorney Tom Rubin has joined its board of directors. Rubin has served as an advisor on IP, legal and policy strategies for many cutting-edge technologies, including artificial intelligence, virtual reality, software services and computer hardware. “We are very excited to welcome Tom to our board and leverage his expertise to grow our business even more,” said Andrew Thompson, AGILE’s Chief Executive Officer. “We are continually developing our products and processes to remain on the cutting edge of in-space propulsion, and Tom’s leadership in both law and policy for key technological advancements ensures we are fully reaping the benefits of our innovations.” Rubin joined AGILE’s board of directors alongside former astronaut Paul Richards in March, when the company shared news of lunar mission propulsion contracts with industry leaders Astrobotic and ispace Technologies. With AGILE’s growth, Rubin brings valuable expertise in intellectual property, technology, data, licensing, artificial intelligence and corporate governance. He worked at Microsoft for over 15 years, spearheading complex IP-related product development and licensing for various business divisions, including Windows, Office, Xbox and Azure. His expertise spans IP, AI, data, privacy, security, antitrust and tech policy, all of which he has recently taught as a Lecturer in Law at Stanford Law School. “In my career, I have had the privilege to see many innovative technologies shape their respective industries. Aerospace is one of these great frontiers, and AGILE is at the forefront of advancements in this industry,” said Tom Rubin. “The company’s advanced additive manufacturing

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processes and sophisticated in-house testing capabilities are reducing cost, shortening lead times and driving higher performance for their in-space propulsion clients. I am thrilled to be joining a team of brilliant minds to help execute on this unique value add.” Prior to Microsoft, Rubin was an assistant U.S. attorney in the Southern District of New York, where he was one of the country’s first computer crimes prosecutors and led many landmark investigations and prosecutions. During his time in private practice, Rubin has represented many notable clients across a variety of industry sectors, from Sony to Spotify. “My career spans more than 30 years in government, industry, academia and private practice, but since my childhood in the early days of the Apollo mission, aerospace and aviation have been great passions of mine,” said Rubin. “I am looking forward to immersing myself in the industry, and to propelling even more growth opportunities for AGILE to reach its next level of innovation.” In addition to his new role at AGILE, Rubin serves on the board of HaptX, a virtual reality company based in his hometown of Seattle, and is a strategic advisor to OpenAI, a research and deployment company for artificial intelligence based in San Francisco. A graduate of both Yale and Stanford, Rubin serves on the executive committee of the Reporters Committee for Freedom of the Press and in a variety of positions at Stanford University.

Mazak HR Director Named to Two Northern Kentucky Workforce Advisory Boards Mazak Human Resources Director William Weier has accepted appointment to two Northern Kentucky advisory boards that guide regional employment policies and align education to employer needs. The Northern Kentucky Workforce Investment Board (NKWIB), which administers federal funding and local policies connecting employers and job candidates, and the Manufacturing Advisory Committee for Gateway Community & Technical College both appointed Weier in April. The organizations’ visions align with Weier’s experience and are essential in supporting Northern Kentucky’s employers and job seekers currently and in the future. Starting out as a machinist at Cincinnati Milacron more than 40 years ago, Weier has experienced the manufacturing world from both sides – on the shop floor making the product as well as from the management side focused on strategic workforce planning in his current position at Mazak. Gateway Community & Technical College is a major influence on the Northern Kentucky economy by providing students the skills and training necessary to support a

variety of regional businesses and industries. “Gateway’s support of educational alignment to the needs of Northern Kentucky industrial partners is critical to providing the skill sets needed for growth in the region,” said Weier. The NKWIB’s focus on career planning and talent development are also important goals for Weier. He said that its initiatives on career planning, diversity through outreach and building a workforce pipeline for the future have also been key strategies for Mazak to develop the next generation of manufacturing leaders. “I feel fortunate to have the opportunity to work with both boards and have a role responding to the needs of the Northern Kentucky industrial community,” Weier said.

Mary Pouliot Appointed Executive Vice President, Americas Thetford North America Thetford LLC, a leader in RV and marine toilets and sanitation solutions, together with Norcold LLC, the premier brand in RV refrigerators (collectively, “Thetford North America”), announced to employees today that Mary Pouliot has been appointed to the position of Executive Vice President, Americas (“EVP”) effective immediately. She will report directly to Chief Executive Officer Stephane Cordeille.

As EVP, Mary will be responsible for the Thetford North America operational and strategic vision. The Americas Management Team will report directly to her. Mary will continue to work closely with the shareholders and the Board of Directors. “Mary’s leadership and dedication to the industry and our customers is second to none. There is no one more qualified or prepared to rise to the occasion and take over the American operations for Thetford and Norcold,” said Cordeille “Mary has been with Thetford North America for over 16 years. She has risen through the ranks from Director of Customer Service to Director of OEM Sales, to VP of Sales & Marketing. No one is more intimately involved with and focused on our customers than she is.” Beyond her tenure at Thetford North America, Pouliot also serves as Chairman of the Board for the RV Technical Institute, Executive Committee Treasurer of the RV Industry Association (RVIA) Board of Directors, Chair of the RV Supplier Committee and is a member of the Michigan Association of Recreation Vehicles and Campgrounds (MARVAC) Board of Directors. She lives in Hartland, Michigan with her husband and three children. “This is an exciting time at Thetford North America. I am eager to take on this new role and determined to continue to advance our progress across our operations and customer support functions,” stated Pouliot.

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Business 4.0

What is the Future of U.S. Manufacturing?

The next decade holds much potential for the industry, with innovation, automation, and a focus on increasing productivity leading the way.

By NRTC Automation

Stronger Emphasis on R&D and Technology In the first months of his presidency, Joe Biden announced the “Made in America” executive order, aimed at strengthening the U.S. economy through nearly $300 billion in investments towards advanced technology and R&D. This was paired with an initiative to create over 5 million jobs in manufacturing. Though these two things can seem at odds with one another, it has been found that automation in manufacturing feeds economic growth in the US, and creates more jobs through the development of new roles, something predicted by the Word Economic Forum a few years ago.

than in previous years. Machines are cheaper, faster, and easier to install, which decreases downtime and increases productivity. Allowing more businesses access to streamlining their production through automation clears the way for new products and solutions to enter the market, another important part of economic growth. Additionally, turning to automation and industrial robots instead of cheaper overseas labor allows more companies to be competitive without having to outsource. This in itself could lead to higher robotic automation over the next decade and could pave the way for a U.S. manufacturing resurgence.

Increased Productivity through Automation Cutting Costs with Automation The advances in technology and machinery also allow for businesses to upgrade more economically and quicker

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One obvious byproduct of automation is increased productivity. A McKinsey study predicts an increase in productivity and growth through automation, worldwide,

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from 0.8 to 1.4 % annually. This production growth positively impacts multiple aspects, from higher outputs, yielding higher margins, to higher wages for employees, and lower costs for customers. This combined outcome only positively affects the economy and workforce. As this barrier of cost for automation drops, and it becomes more accessible, the market should see more businesses turning to industrial automation on various scales. When this happens, the market will be able to see not only more innovative products produced on a larger and quicker scale, but the quality increasing with production speed.

More Manufacturing Jobs Manufacturing, although not as much of a job supplier as it used to be, is still one of the leaders in employing workers, especially in middle-America. And experts expect this to continue, and even increase, as the industry bounces back from the pandemic.

Manufacturing makes up the largest employer group in the U.S., and is one of the highest employers of adults with GEDs or high school degrees that may not have a bachelor’s degree, which is currently half of the country. It’s important to not only provide jobs for those that may not have a college education, but encourage those that may not into productive and thriving positions, in such fields as manufacturing.

Automation Solutions NRTC can help with automating and streamlining your business. We offer turnkey solutions for manufacturing businesses, and provide production support ranging from basic to advanced. We can help design, build, engineer, and install a customized industrial work cell for your business, as well as help you troubleshoot any issues you might be having with your current line up, and find a solution that can work for you. We’re ready to help you improve your efficiency

and productivity, and move you into the next decade up to par with the quick evolution of the industrial manufacturing industry.

How Will Manufacturing Facilities Change in the Next 10 Years, and How will Manufacturing Evolve? Predictive Maintenance Will Take the Forefront Predictive maintenance uses computer AI and sensors installed throughout production lines to proactively alert operators of potential maintenance issues or failures. If manufacturers can stay on top of potential issues, there will likely be less downtime and issues with production. As technology advances, manufacturers are not just purchasing newer industrial machines and robots with these sensors but installing them on older equipment. Manufacturers that have done this are able to analyze data and then interpret a machine’s

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condition, fix machines before they break or fail, and find irregularities that may lead to downtime.

Real-Time Manufacturing Over the past few years with the effect that COVID-19 had on production facilities, many industries are moving to a thinner and scaled-back inventory. Automation and AI are helping manufacturers keep only what is necessary on the shelves and using their current technologies, machines, and industrial robots to keep supplies moving through the production line as soon as they enter the building. Efficiency will be ramp up and create more space in a warehouse, allowing companies to expand and increase production.

Infection Control through Automation Coronavirus changed the way many businesses functioned and influenced the way employers looked at health issues within their facility. Masks, hand sanitizers, and additional health protocols were put in place across the world in order to curb the spreading virus, and many of those are still in place today. And one of the biggest moves that companies made included adding robots to their assembly lines and production facilities. Industrial robots and machines don’t get sick, and therefore don’t take sick days or need recovery time. Many manufacturers have implemented automation and replaced human workers with robots as a preventative measure, should a worldwide pandemic strike again. Production can be maintained with industrial automation, and human interaction can stay contained and limited. As technologies grow, robots and automation replacements are becoming increasingly widespread. Today, there are even fully-automated factories and job sites known as “dark factories” that require no direct human interaction on-site.

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Working with Robots Manufacturers aren't just looking to replace their employees with robots, but they are also searching for ways to integrate robots with their employees. These “cobots” work side-by-side with humans in warehouses and production lines in collaborative environments. Not only can cobots assist with efficiency, but they also aid in maintaining safety protocols, performing tasks like heavy lifting or working with extreme heat sources without risk of injury. Intelligent robots can work in tandem with employees on the floor, speeding up production and increasing efficiency.

Sustainability Focus Manufacturers are moving toward greener and more sustainable production methods, thanks not only to public pressure and scrutiny, but also government efforts like the Clean Water and Clean Air Acts. Refurbishment of existing robots and machinery keeps costs, as well as environmental impacts, low. Buying used machinery reduces carbon dioxide emissions, and other types of pollution, and can be updated to fit seamlessly into production lines. When an industrial machine can no longer be used, companies are learning how to properly dispose of machines without just tossing them out with the trash. Our partner HGR works to recycle up to 95% of most industrial machines that cannot be resold or repurposed, helping to keep pollutants out of landfills and the environment.

NRTC Automation Keep You Updated NRTC Automation ensures our customers are at the forefront of changes in the industry and keeping with up-to-date technology. Whether we are helping to update and automate your facility, or designing a custom part for your newly refurbished industrial robot, NRTC can assist businesses

in moving forward. To learn more about how our services could positively impact your production, visit www. nrtcautomation.com/automation

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Talking Shop

Our goal is to support the entire global supply chain as “a force for good” in the world.

FEATURING:

TALKING SHOP WITH: Abe Eshkenazi — CEO, Association for Supply Chain Management I’ve enjoyed learning about ASCM. When was it founded, and how has it coalesced over the years? The formation of this association was truly a grass roots effort. In 1957 state chapters realized the need to consolidate and organize into a cohesive association that would both represent and legitimize their work. These individuals were involved in everything from procurement, to logistics, to warehousing, and so much more. They realized they needed to speak with one voice, and even to develop a common language. One of the first efforts undertaken involved creating a dictionary to help unify all the disparate terms used in so many different occupations that, in reality, shared a common bond. That dictionary is now celebrating its 12th edition, and has played an incredible role in uniting the members of what used to be called “Industrial Design,” and is now known as the supply chain. Although the original efforts centered around Cleveland, Ohio, and were carried out among different chapters, we are now headquartered in Chicago with a staff of around 100 people.

Who are your members, and what benefits do you provide as an association? They’re involved in manufacturing, distribution, transportation, and a host of other specialties. ASCM serves its member companies, which number around 60 in the United States and 120 overseas, by offering a central point of contact for everyone involved in the supply stream. And the relationships we’ve built with similar associations located around the world allow us to share

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different approaches to challenges we all encounter in our work and also for us to be aware of conditions occurring elsewhere that might affect our U.S. membership. In addition, we hold a Trade Show each year in Chicago, and we produce a host of publications to aid our U.S. constituency in weathering whatever challenges may occur in the future. We’re active in disseminating the information that we and our members produce, both online and in print, and we’ve been heartened by the college degrees now being offered in the supply chain management field, along with the certification programs we provide – we’re at 125,000 graduates and counting. Our goal is to support the entire global supply chain as “a force for good” in the world.

Do you think the growing awareness of supply chain issues in the national media has been beneficial to your work in any way? It definitely has. The concept of a “supply chain” being featured in major media outlets has helped everyone to think about how the products they purchase are actually delivered to them. People don’t really think about how many miles a machine part, or even produce, travels before it reaches them. In this business, we experience disruption after disruption, and in ways that simply can’t be predicted beforehand. That’s why we keep our finger on the pulse of the global supply chain, so that we and our members will be better prepared to weather any upcoming storms. For more information please visit www.ascm.org.

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Safety & Maintenance

Industrial Production: Eliminate Indoor Airborne Contaminants to Protect Worker Safety, Productivity

Air purification systems can capture smoke, exhaust gasses, and pollutants from welding, plasma cutting, combustion, and other sources

By: Del Williams

n industrial settings, noxious airborne contaminants from a variety of sources can jeopardize indoor air quality, compromising worker health, productivity, and even regulatory compliance unless the air is sufficiently purified when ventilation alone will not solve the problem. Welding, plasma cutting, or combustion processes including engines and generators can produce noxious smoke and exhaust gasses. Fugitive emissions can include fumes in chemical processing as well as dust and trace metals in metallurgy. Industrial solvents can contain chemical aromatics like benzene, toluene, or xylene. Spraying paint or other substances can leave chemical mists suspended in the air. Various processes

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and cleaning routines can release a complete spectrum of often harmful VOCs. Regulatory agencies like the Occupational Safety and Health Administration (OSHA) set permissible exposure limits for many toxic substances and the National Institute of Occupational Safety and Health (NIOSH) also sets indoor environmental quality standards, which includes air quality. To effectively protect industrial workers, productivity, and compliance, one solution is to install “smoke eaters,” advanced air purification systems that filter large volumes of air quietly to remove smoke, air contaminants, and even odors. In doing so, the contaminated indoor air is passed through a series of sophisticated filtration media

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that eliminate harmful particulate before the cleansed air is released back into the work environment. “By providing cleaner air and removing irritants and potential toxins, industrial personnel can not only breathe easier, but also work more productively. The approach can help to improve long-term employee health, absenteeism, and retention, which are important concerns in today’s tight labor market,” says Randolph Bush, owner and President of LakeAir, a Racine, WI-based manufacturer of industrial, commercial, and residential air filtration systems since 1968. Recently, a growing number of manufacturers and industrial processors have sought to purify their indoor air with advanced “smoke eater” air filtration. Because the requirements can vary considerably, companies like LakeAir consult with the manufacturer to determine the best air filtration based on the application, physical layout, square footage, as well as the expected number and volume of “smoke” generating processes at the jobsite.

“Differences in particulate size, type, and the desired number of air exchanges per hour, as well as other factors should be considered,” says Bush. According to Bush, one of the most versatile commercial air purifiers for industrial applications utilizes multiple stages of filtration to remove 97% of particulate down to .01 microns and cleans up to 2,000 cubic feet

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per minute of indoor air. First, a prefilter catches larger debris in the airstream like bigger pieces of dust or particulate. Next, comes two separate electrostatic cells, each with two stages of electrostatic air purification. In the first stage, the smoky air is drawn through the particle ionizer. Here, the smoke in the air is given a negative charge. The second stage is a collection plate, where the charged particles of smoke and contamination are attracted to each plate and trapped. The contaminants remain on the filter plates until they are removed when the filter is washed. Finally, an activated carbon filter traps any remaining contaminants as well as odor molecules by adsorption inside the pore structure of the carbon substrate. After passing through the commercial filtration systems, purified air flows back out into the indoor work area. “Manufacturers benefit from a longer filtration section because the longer the particles are filtered, the more likely they are to be trapped,” says Bush. He notes that the commercial air purifier’s filtration section is 10-inches thick, including the dual electrostatic cells that provide over 26,000 square inches of collection area for contaminated particles. The compact dual cell design allows more air change cycles for the available space than other technologies while keeping operational noise to a minimum. According to Bush, the air purification units are often used in industrial settings like welding rooms, paint prep areas, machine shops, and manufacturing floors. To suit the specific design of the room, the units are typically hung from the ceiling by chains or mounted to a wall. In terms of reliability, the electrostatic cells in the industrial air purifiers are built to last with non-corrosive materials. “Some of our cells have been in service for more than 30 years,” says Bush. The air filtration units are made in America with heavy-duty, all-steel construction for durability.

As industry seeks to safeguard worker health and increase productivity, the use of advanced smoke eater air purifiers that continuously cleanse indoor air will become more prominent. The ability to tailor the air filtration system to accommodate the manufacturer or processor’s specific needs will increase its adoption across an even greater range of applications. For more information, call 800-558-9436 or visit www.lakeair.com.

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Manufacturing Showcase

Global Equipment Manufacturers Serve Life Sciences and Biotechnology Companies on Cloud ERP Meeting the world’s urgent and increasing needs for laboratory and medical testing products, Hamilton Company expanded its business during the pandemic after deploying Microsoft Dynamics 365 Finance and Operations (also known as D365 Finance and Supply Chain Management) with assistance from Sikich. By Hamilton Company

Enabling Labs to Fulfill Their Mission Around the globe, laboratories and companies in the life sciences and biotechnology industries rely on automated liquid handling workstations, precision measurement devices, robotics, process sensors, pipettes, and other products from Hamilton Company. The business began in the late 1940s by developing microliter syringes in Clark Hamilton’s garage, soon won a contract from the Swiss government, and continued to grow. Today, Hamilton has offices and customers worldwide. Its main administrative, design, and production locations are in Reno, Nevada, and Franklin, Massachusetts, in the U.S., and in Bonaduz, Switzerland. Hamilton was key to helping the world manage the COVID-19 pandemic. During 2020, the company saw a more than ten-fold increase in orders for its liquid handling robotic equipment. In collaboration with General Motors, Hamilton

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stood up a manufacturing facility for ventilators in Reno in order to meet the needs of the federal Department of Health and Human Services and healthcare providers in the U.S.

Complex Manufacturing Business Looks for a Cloud Solution Company operations in the U.S. and Switzerland ran on legacy business management software that was several decades old. In its new ERP environment, Hamilton would need to manage an extremely complex operation that comprises configure-to-order and engineer-to-order processes. The system had to support multiple lines of business through the development, design, and production of multiple platforms for Hamilton automated liquid handling robotic equipment while also facilitating the higher-volume business of syringes, pipettes, and other products. In addition, the company sought to manage its services under the same software solution.

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

For customers, Hamilton technicians install the robotic equipment and provide maintenance services to keep it running at optimal performance.

Leading this business change, the Swiss location selected Microsoft AX 2012 with assistance from a local partner. Hamilton decision-makers agreed. By the time the Swiss implementation project started, Microsoft had introduced Dynamics 365, so the Swiss implementation changed from AX 2012 to the new product. It was important to Hamilton that Dynamics 365 was continuously evolving with new and augmented capabilities. “We wanted a software product we could grow with far into the future,” Ingram says. “Microsoft continues to invest in and improve Dynamics 365.” Hamilton leadership in the U.S. closely observed the experience of their European colleagues.

ERP Project Led by IT and Business Groups Following the Swiss go-live, Hamilton applied lessons learned from that project. Hamilton determined a businessdriven approach was best. In the past, the IT department led systems implementations with minimal input from the business groups. This time, IT and business teams were going to collaborate. Involving business stakeholders throughout the effort would help ensure that the new ERP system would meet the company’s needs. It also would lead to faster, more widespread user adoption. Hamilton recognized the need for a new technology partner to help implement Dynamics 365, and interviewed several firms. Ingram says, “Sikich came highly recommended, and we were intrigued by their ERP recovery services, which turn around struggling projects to be successful. We needed a consulting partner who understood the configure-to-order and

“Sikich came highly recommended, and we were intrigued by their ERP recovery services, which turn around struggling projects to be successful […] We didn’t have to spend time educating the Sikich team about how our business was run. They understood it from the outset.” Alex Ingram, IT Director, Hamilton Company

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“We had a good working relationship with the Sikich team members. They were good communicators who helped us understand what we needed to do in order to have a successful implementation.” Alex Ingram, IT Director, Hamilton Company

engineer-to-order business, and saw quickly that Sikich was very familiar with our operating model. We didn’t have to spend time educating the Sikich team about how our business was run. They understood it from the outset.”

Fast Deployment with Remote Partner Collaboration Together, Hamilton and Sikich prepared an implementation of Microsoft Dynamics 365 Finance and Supply Chain Management. “We had a good working relationship with the Sikich team members,” Ingram notes. “They were good communicators who helped us understand what we needed to do in order to have a successful implementation.” In this project, Sikich used its HeadSTART for Equipment Manufacturing methodology. HeadSTART streamlines complex software projects with a large arsenal of standardized processes based on industry-best practices. In most projects, these already satisfy most of a company’s requirements. As Ingram describes, “The Sikich HeadSTART approach provided a preconfigured solution that allowed us to move forward much more quickly than we had been. About 90 days in, we were ready for our first conference room pilot using HeadSTART. People were saying, ‘We could go live with this.’” Jon Fondi, Purchasing Manager at Hamilton, adds, “Out of the box, we had a similar or better product than what we had in our old system.” The deployment project began during the worst of the pandemic. Hamilton paused it for a few months to concentrate on its most urgent business priorities, but then completed it efficiently by working remotely with the Sikich consultants. Ingram notes, “Remote consulting can work for an implementation project — you don’t have to be onsite. Some of our project team members had to pay close attention to the business. Scheduling meetings in Microsoft Teams allowed them to engage more fully with our consulting partners.”

Achieving Scalability and Simplifying Frequent Tasks Soon after the implementation, Hamilton realized that it had made the right choice in Microsoft Dynamics 365. “During the pandemic, we more than doubled in size in terms of the number of employees, and revenue also more than doubled as we were responding to the world’s needs,” Ingram says. “Dynamics 365 has grown with us. We haven’t had any issues in scaling to increased numbers of employees, more work centers, or expanded business operations.” Hamilton also registered many small improvements following the go-live of Dynamics 365. As an example, Fondi discusses one frequent task, generating purchase orders. “When it used to take us an hour or two to organize a purchase order, this will be going down to minutes. We can combine and consolidate orders for the same vendor into one purchase order. The system creates the POs for us, rather than us going in and manually generating POs and putting in part numbers,” he says. Many manual steps of repeated data entry and recording information have fallen away. Fondi continues, “The system really will benefit us by reducing the amount of human error, because it does not require copying and pasting or even typing. In both the requisitioning process and the conversion of a planned order process, you don’t have to type. The ability to take planned orders, items, requisitions, and convert them without additional input — that’s huge.”

Gaining Intelligence in the Cloud Hamilton broadly uses Microsoft Dynamics 365 to manage its operations, including field services. Some areas of the business, like human resources, receive focused attention to garner the best value from the new ERP system. Business users appreciate that Dynamics 365 integrates with business intelligence and analytics tools on the Azure cloud. Commenting on these integrations, Ingram says, “That’s something that will save us time and money as we look to

“The system really will benefit us by reducing the amount of human error, because it does not require copying and pasting or even typing. In both the requisitioning process and the conversion of a planned order process, you don’t have to type. The ability to take planned orders, items, requisitions, and convert them without additional input — that’s huge.” Jon Fondi, Purchasing Manager, Hamilton Company

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provide dashboards and information to our end users. Native integrations means that we don’t have to build things from scratch. There’s a tremendous advantage for us on the analytic side of the business.” Dynamics 365 serves Hamilton as its main business management system. “It gives people comfort that we will be on a single solution set, relying on a single vendor,” Ingram comments. “When we implemented Dynamics 365, we fully replaced existing systems, and we haven’t had to build any complex integrations.” Because many developers and solution architects grow their careers on Dynamics 365, Power BI, and other Microsoft cloud software, Hamilton has found it easy to recruit skilled talent to help manage its ERP environment.

Best Practices Ensure ERP Success Business stakeholders participated with the IT team in a close collaboration to prepare and perform the ERP implementation. Together with Sikich consultants, IT and business stakeholders VISIT performed repeated, thorough rounds of testing, ran Dynamics 365 through many business scenarios, and adjusted the software to be more usable and more closely fit business processes. “With the help of the technical resources from Sikich, we ran through multiple data conversions during each of our conference room pilots,” Ingram describes. “We were able to convert more data each time. By the time we got to conference room pilot four, we were doing a full data load, and we repeated that data load for our user acceptance test. Then we did a mock go live with another full load.”

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In Dynamics 365, Hamilton will continue to find greater efficiencies and improve its management of production, the supply chain, and other areas of the business. An automated, third-party warehouse management solution will soon integrate with the ERP platform. “We don’t necessarily know where business is going to go for Hamilton,” Ingram concludes. “But we know that whatever direction we go in, Dynamics 365 will be capable of supporting us.” INDUSTRIAL MACHINERY DIGEST.COM

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New Technology

Aerospace and Defense Manufacturers Must Prepare for the Robot Revolution

Like all manufacturers, aerospace and defense firms must engineer existing or new facilities in preparation for much higher levels of robotic automation. To do otherwise places them at a competitive disadvantage. By Josh Tuttle

egarding robotics, the future is the present — in that it is already here. For advanced economies, robots are providing domestic companies with the efficiency edge they need to support the reshoring trend where manufacturing production returns from lower-wage manufacturing outsourcers located in other parts of the world. But you cannot simply deploy robots into existing manufacturing plants and expect things to move smoothly. Plants must be retrofitted or even redesigned to make the most effective use of this new 24/7/365 workforce. Additionally, new plants should be built around the robotic operations to ensure safe and smooth workflows throughout the facility. Consider an aerospace or defense manufacturer that is preparing to build or renovate a facility they plan to use for the next 10, 20, 30 years or longer for multiple product lines. That building and infrastructure need to be futureproofed to ensure that, as well as being suitable for current work processes, they’ll be adaptable and cost-efficient for the newer processes that are coming. Partnering with a key robotics integrator in the planning phase is a crucial step to ensure your company has the correct floorspace, excess utilities and electrical expansion capabilities. This will also help to avoid common problems like having to upgrade a brand-new building because no one asked the right questions. Here are four ways in which aerospace and defense manufacturers can prepare for the robot revolution:

1. Leave Disappointments in the Past Robots have been available for years, and perhaps your company has tried them in the past, with results that did not impress. If so, do not remain anti-robot. Today’s robots are already better than the ones that let you down yesterday, and tomorrow’s robots will be even better still. Plus, it is not the robot that failed, but the process. All good robotic integrations are process driven with clear expectations established. If those aren’t clear at the

All good robotic integrations are process driven with clear expectations established. If those aren’t clear at the beginning of the project, it probably won’t be very clear at the end either. 28 | IMD

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

Also, maintenance personnel who understand the equipment are a must, regardless of whether they’re internal or in partnership with your integrator. beginning of the project, it probably won’t be very clear at the end either. If the process still needs to be defined, the best place to figure it out is in the lab. At our robotics company, we leverage our in-house lab on almost every project to eliminate any potential risk. The lab can be used as an early technology demonstrator before the project gets started. This is the lowest risk and cheapest route to a successful robotic system.

2. Future-Proof Your Infrastructure Even if your company will not be using robots much in the short term, you should take their needs into account when building a new manufacturing plant or refitting an existing one. By making minor adjustments to ensure your plant is robot-future friendly, you can spare yourself the major expense of having to do a total rebuild or refit in five, 10 or 15 years from now. Building the “Factory of the Future” begins today. Robots consume a lot of power and company’s need the grid to support them. Along with the robot, all the ancillary equipment has some hefty power requirements. It’s safe to estimate a traditional industrial at peak usage

will use 30 amps at 480 volts and the newer collaborative robots can run off of 20 amps at 120 volts. When you start pairing multiple robot cells together, it can add up quickly. As robots become smarter and are being integrated with more sensors, they have more data that they’re harvesting. What good is all that data if it’s stuck on a PC? Setting up a network for your robots to operate on is more than just plugging in an Ethernet connection. Automation equipment and robots need their own independent network to communicate with each other. Working with your robotics partner to set up a system network diagram early on will help you and your IT team understand the network needs for the robotic systems.

3. Hire the Right Humans As more aerospace and defense manufacturers integrate robots into their work processes, their human workers need to include the right combination of computer- and mechanical-savvy operators. A good robotic system operator needs to be comfortable sitting behind a computer or a teaching pendant, but also knowledgeable enough to troubleshoot a system alarm on the robot. Do not

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neglect mechanical or software engineers either, because robot support teams require both. These should be skilled operators who understand the process, whether it's painting, drilling or machining. Also, maintenance personnel who understand the equipment are a must, regardless of whether they’re internal or in partnership with your integrator. There remains a fear among some that robots will take more jobs away from humans than they create, but the World Economic Forum predicts that this will not be the case. The jobs that will be eliminated are largely the ones that are the least attractive for humans, or that had previously been shipped offshore. They will include positions that are unsafe, repetitive or that must be performed in extreme temperatures – so-called “3D” jobs that are dangerous, dull or dirty. The jobs that the robot revolution will create for humans will be more highly skilled, interesting and challenging – and ultimately more satisfying.

4. Make Your Robot Fleet Flexible Don’t be afraid to think big. Your manufacturing needs will change – day-to-day, project to project and over time. So, when you invest in robots, invest in applications that the robot will be doing today and possibly doing in the next few years. Might you be using mobile robots, automated guided vehicles or, even, mobile multi-use robots for new, advanced projects and products? Consider what these robots could be doing in the next five or 10 years and how else they can be utilized in the future. Talk to your integrator about what robot is best

for the application needed and what other potential applications are best for your robot. Be specific about what you want the robots to do, have a broad vision for your robotics solution and group your robotic operations together. A robot that has the ability and power to pick up heavy weights might not be the same robot that’s needed for more delicate projects like precision painting. Think about how you want your robots to function and the multiple tasks you might require of them before committing to buying a fleet of robots.

Final Thoughts Companies can and will save substantial amounts of money by taking the requirements of a robotic future into consideration when making business decisions today. Ultimately, businesses that do not embrace this robot revolution will be left to play catch-up when robots become indispensable in helping manufacturers stay competitive and innovative. Start the process for your plant or facility now so that you’re a part of the revolution, rather than being upended by it later. ABOUT THE AUTHOR Josh Tuttle is the Business Development Manager at Aerobotix, an innovative leader in advanced metrology and robotic solutions for the aerospace and defense industries. The company specializes in the creation of cutting-edge automated robotic solutions for high-value, high-precision components, aircraft and vehicles.

Automated Storage and Retrieval System Elevates Cobot Productivity

Applied Cobotics has taken another innovative step forward with the introduction of the Automated Storage and Retrieval System (ASRS). This brings another piece of the automation tool to our collaborative robot system, offering more production power, flexibility, and ease-of-use. This is especially important to small- and medium-sized enterprises (SMEs) that are looking to incrementally increase their automation. By PBC Linear

ithin the factory of the future program at Applied Cobotics, we have readily embraced the cobot (collaborative robot) nation. Initially, as we were implementing this new technology, we found that one tray of parts did not take advantage of the cobot’s full potential. We quickly realized that we needed some type of lift automation, combined with a storage and retrieval component, that would assist the cobot for much longer unattended production runs. The solution? We designed and built the ASRS to enhance any robot's productivity, run a higher mix of parts, and ultimately recoup a greater return on investment.

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Collaborative technology for more production power The ASRS assists most cobots and other robotic applications by providing a continuous arsenal of machinable parts over a much longer time frame. It does this by consistently loading and unloading dunnage trays onto the robot accessible work area, eliminating the need to manually

replace each one. The resulting boost in cobot production is 10- to 20-times that of standard means. The ASRS from Applied Cobotics features a vertical lead screw-driven shelf, and a horizontal tray loader/unloader. In addition, tray rack towers engineered for the ASRS offer open-spaced shelving that accommodate various part sizes up to 18-inches in height. The rack towers are also capable of holding up to 17 trays. Customized dunnage parts trays can be acquired either through our 3D printing and thermoforming capabilities. For DIY customers, purchase one of our 3D Platform or BCN3D printers and create your own custom trays! The ASRS works by assisting a robot in longer parts runs. Without the ASRS, a robot will stop running as soon as it finishes that one tray of parts. With the ASRS in place, the robot system is capable of unmanned, continuous production. As the cobot finishes each set of parts on the tray, the tray loader slides the finished parts tray to its predetermined position, and then pulls the next one onto the shelf. Once the tray is pulled into position, the cobot is alerted and automatically resumes its project tasks. Depending on the parts, a project can operate unaided overnight, making each one a potential lights-out automation run. Built-in motor encoders provide highly accurate motion, maintaining the tight tolerances that cobots require. All together, these features provide reliable and safe load-handling for any part type or size. The ASRS can easily be implemented to automate most CNC lathes, Mills, and many other types of robotic-aided manufacturing for long-running, unattended operation. ASRS is offered as a package deal with an attached cobot, or as a single component.

Flexibility in Automation As customers begin to request more custom components, shorter part runs, and cheaper costs, there is an increasing demand for flexibility on the shop floor. The Automated Storage and Retrieval System from Applied Cobotics, in tandem with many types of robots, provides project managers and operators that flexibility. While Applied Cobotics offers the ASRS and cobot as a package deal, the ASRS can be purchased on its own, providing an essential asset to existing automation systems. It offers its own adaptive features such as: » Compatibility with any cobot/robot with I/O ports » Compatibility with any cobot-suited application » Multiple parts programming options within one job run » Production of an entire cart of trays in conjunction with robots » Pallet jack accessible design for portability » Mobile tray rack that can be moved from station-tostation and locks easily into place

Easy to Use and Install The ASRS from Applied Cobotics is easy to use, and does not require any extensive programming knowledge. For CNC milling machines, our experience has proven that the time investment is less than one day to fully implement the

ASRS/cobot package. Other ease-of-use features include: » HMI touch screen display for easy control » Software Interface that can be programmed in a few simple steps » Removable cart for station-to-station mobility » Optional camera and monitor screen allows operators convenient production viewing Additionally, the safety characteristics of cobots have been applied to the automated material lift system. If a human worker or any object gets too close to the ASRS, a floor sensor will alert the ASRS to pause its motion until the area is clear again. Use any of the links below to find out how Applied Cobotics is making automation easy for SMEs. For more information, visit www.pbclinear.com.

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Process

The Great I/O Migration

Planning an effective, efficient I/O upgrade means partnering with automation experts

any processors, even those with modern distributed control systems (DCS), a system of sensors, controllers, and associated computers that are distributed throughout a plant, continue to operate with outdated input/output (I/O) components. I/O transfers information between the computer's main memory and the outside world. Despite its long-term contribution to operations, I/O is one of the most significant investments in an automation upgrade. Justifying the risk and expense of I/O upgrades to management is a challenge, and often, it is easier for processors to delay upgrades year after year. “While a phased approach to migrating from older systems to newer technology is preferred, we find it is often difficult for processors to determine just when and how to make the switch to modernized I/O,” says Mike Davis, process product manager for NovaTech Automation, a Pennsylvania-based automation provider. “Some of the old systems are still reliable and that is a major part of the problem. Engineers want the latest and greatest, but it can be hard to justify the costs.” According to Davis, the decision to modernize should be based on NovaTech has also developed conversions for the TI/Simatic 505, Modicon 200, and Allen-Bradley I/O whether a processor can continue to to the8000 series. operate reliably and safely with the services designed to assist in modernizing I/O systems existing system. Key considerations include whether spare while minimizing downtime. or replacement parts are still available, whether system performance issues are beginning to appear, and the availability of training and support required to keep legacy The Great Migration systems and subsystems running. The impact and cost of An I/O migration typically begins by upgrading to an unexpected shutdown should also be considered. the latest version of the existing DCS system, if “Many process manufacturers come to us with I/O, needed, which serves as the hub of a processor’s controllers and other components that are 30 to 40 years operations monitoring key variables such as flow, old,” explains Davis. “As I/O ages, there can be increasing applied temperatures, pressure, level, and material risks. For a plant of any scale running at or near capacity, conveying/handling. taking down processing lines for any amount of time can A detailed site survey is critical to determine be extremely expensive in terms of lost production and the scope of the upgrade. Will the existing cabinets business impact.” be used, or will new cabinets be required? Can the However, the challenge in migrating I/O is that there existing I/O be retrofitted with conversion kits from is not just one solution. Different approaches and even the original manufacturing? Will the I/O require wiring custom solutions are required depending on the type of or use interface boards? Will new communication I/O being replaced. Fortunately, there are products and controllers be required?

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

To modernize I/O on its D/3 DCS, NovaTech typically installs 8000 I/O, a highly reliable I/O system with a full range of module options

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To modernize I/O on its D/3 DCS, NovaTech typically installs 8000 I/O, a highly reliable I/O system with a full range of module options. Within each 8000 Series node, up to 64 I/O modules can be supported, with 4 to 32 channels per module. The 8000 Series has fully integrated configuration, status display, and diagnostics with NovaTech’s D/3 DCS to facilitate greater automation with better diagnostics, troubleshooting, and asset management capability. With this combination, operators can remotely drill down to the controller or I/O card without having to go into the field. First introduced in 2006, NovaTech continues to upgrade the 8000 series, including a redesign for RoHS compliance and product enhancements, including 16 channel HART analog input, 32-point FTA, and new EBIM (Ethernet Bridge Interface Module) and EBIM carriercomponents.

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Fortunately, there are products and services designed to assist in modernizing I/O systems while minimizing downtime.

For a complete I/O upgrade to be successful, Davis says it is invaluable first to conduct a site survey. Time spent upfront to determine the scope of the upgrade will pay off by ensuring the installation is performed expeditiously and properly. This can include determining if the communication controllers also need to be replaced, the state of the wiring, the electrical requirements, and available footprint/cabinet space.

I/O system components can be mounted and connected in multiple configurations on the DIN rail. EBIMs in their carrier are connected to I/O carriers directly or through cables, in horizontal and/or vertical configurations to a maximum railbus length of 21 feet. “We do similar cabinet designs each time, but there is always something different to consider at every site, in every cabinet, that is unique. The flexibility in connecting and mounting the components allows us to accommodate various size cabinets or small footprints and a pre-assembled, pre-wired cabinet can be installed quickly during a planned shutdown,” says Davis. NovaTech can custom design and install components on mounting panels if a cabinet is not required. “Usually, the shutdown needs to be as short as possible, so having everything ready and tested and the software configurations completed as much as possible ahead of time is a major contributor to a successful migration,” says Davis.

Assembled, Pre-wired, and Tested Systems

Conversions from Aging I/O Systems

There are advantages to having the complete system assembled, wired, and tested in a cabinet or on a mounting plate before it is shipped to speed up the installation. Depending on the size of the existing cabinet (in a retrofit) or the available footprint for a new cabinet, the

I/O hardware obsolescence is a problem that even manufacturer’s like NovaTech face. “As a supplier, we are finding it harder to continue to support the older legacy I/O, both from a hardware and software standpoint. That is why we continue to invest in developing native I/O systems like the 8000 Series that work

To increase reliability, redundancy is built into the I/O system design. The 8000 Series features dual redundant Ethernet communications and an optional 1:6 module redundancy scheme that backs up individual I/O modules for increased reliability. In the event of an issue or anomaly, the system can switch to a backup module on the carrier. The EBIMs also provide dual redundant communications between the PCM and 8000 I/O modules for high system availability.

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with our D/3 DCS system and Ethernet, while moving away from non-Ethernet protocols,” says Davis. In fact, NovaTech invested considerable time and money to develop a new CPU for its 4000 series PCM process controllers, because the original motherboard was no longer available. The company also developed a next-generation controller, the PCM5, which provides integral secure boot and firewall, allowlisting, and other cybersecurity features. To replace older systems installed in the ‘80s and ‘90s, NovaTech provides conversion utilities for its 16000 I/O series and manual conversion for other I/O types. “In 1982, the 16000 I/O was introduced and over time was re-engineered and improved. In 2013, 31 years after its introduction, NovaTech entered ‘repair and replace status’ for the 16000 I/O because some of the parts could no longer be manufactured. You can manufacture a PC board, but many of the chips and

other components that go on it just are not available anymore,” notes Davis. The 8000 Series can replace the 16000 Series in existing PCM cabinets, using existing field wiring connected to new termination panels with existing connectors. It can also replace the Quantum I/O first integrated with the D/3 by NovaTech in 1994, which is no longer supported by its manufacturer due to component obsolescence. NovaTech has also developed conversions for the TI/Simatic 505, Modicon 200, and Allen-Bradley I/O to the 8000 series. “Running to fail is not a long-term solution,” says Davis. “Recycling and refurbishing old parts or turning to eBay is not a sustainable strategy.” For processors that want to understand their obsolescence risk and prioritize modernization needs and goals, a life cycle analysis is recommended to assess the equipment, spare parts, and software inventory.

Because no two control systems are alike, each upgrade also presents unique circumstances that prevent utilizing a cookie-cutter approach in the preliminary engineering and quoting process. For this reason, partnering with an automation expert is highly advised. “Processing companies need to perform a thorough assessment of their control system, with an automation expert that can make recommendations on which equipment should be upgraded first. Having a concise plan and roll-out schedule is essential to a successful modernization effort because it is a big project,” says Davis. Due to the fact that in migrating I/O there are a variety of different approaches and even custom solutions available, depending on the type of I/O that is being upgraded, it’s important to work with a partner and develop an effective plan to minimize downtime and maximize the lifespan of the system.

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IMD | 35

Industry Insight

Precision Aerospace Machine Shops Leverage Adaptability and Nimbleness to Respond to Complex Machining Challenges

Nimbleness and adaptability are needed to be able to scale production up quickly.

ithin the dynamic aerospace and defense sectors, changes to part specifications and quantities are frequent and often unpredictable. As a result, clients require a machining partner who can nimbly and quickly adapt to design and production changes as they occur and be capable to scale up to ‘lights out’ manufacturing when needed. “Aerospace and defense customers may prefer large machining operations,” said Tony Doan, CEO of Halcyon Manufacturing, an advanced ITAR registered and AS-9100/ IS-9001-certified machining shop based in San Jose, California. “But size alone does not equate to capacity. Smaller shops can have an advantage when a client needs a machining partner to also be nimble and flexible. For our clients, the ability to adapt and problem solve is incredibly important as complex manufacturing requirements frequently evolve and change.” “Aerospace machining involves a lot of low volume, high mix work,” adds Doan. “The reality is not every machine shop wants to take on small orders or highly complex jobs. A client needs a machining partner who

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really embraces this kind of work in addition to the high-volume orders.” When evaluating the capacity of a precision machine shop, the capability to respond to changes in specifications and production quickly becomes a key factor. Nowhere is this more acute than when an aerospace client has a priority aircraft on the ground (AOG) machining order. Until the AOG gets filled, an aircraft will not be able to operate making response time incredibly important. Unfortunately, an AOG order is never predictable and can happen at any time.

Building capacity through cross-training Staff cross-training is one way a machine shop can improve their ability to respond to unexpected and time-sensitive machining needs such as AOGs. While today’s machine shops are filled with a mix of high-tech precision CNC equipment, each requires trained staff to manage, maintain, and operate. “A lot of aerospace machine shops will assign an operator to a specific CNC machine,” said Doan. “This can

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

create a situation where a particular operator has to be available and not working on other orders, to operate a given machine.” Having the ability to move people from machine to machine, as well as from line to line and from shift to shift, without interruption enables a machine shop to respond to changes in demand more quickly. At Halcyon, where they machine bar grade 6061 aluminum, brass, copper, titanium, stainless steel, and plastics, they have cross-trained their entire staff to work across all their When evaluating the capacity of a precision machine shop, the capability to respond to changes in specifications and equipment to maximize production quickly becomes a key factor. their capability for scale up. completely rethink how we’re going to schedule. We can “We have not only cross-trained our team, but we easily plug in people for surge hours or to increase our all work multiple shifts, and we have the same controls manpower as needed.” throughout our shop,” said Doan. “It makes it easy for our The company made the decision to further enhance people to be able to move around as needed. So, when a their cross-training through their selection of machining client needs something over a weekend, we don’t have to

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Halcyon intentionally purchases the same model of high-end 5-axis CNC machine from Doosan Machine Tools with FANUC controls as they expand.

equipment. Unlike shops that purchase a variety of types and brands of CNC equipment over time, Halcyon intentionally purchases the same model of high-end 5-axis CNC machine from Doosan Machine Tools with FANUC controls as they expand. This further reduces the learning curve for their staff.

Lights out manufacturing capability Nimbleness and adaptability are also needed to be able to scale production up quickly. Some machine shops such as Halcyon operate on a 24/7 basis enabling customers to connect with them outside of traditional office hours. “‘Lights out’ manufacturing takes scaling up production to the next level,” says Doan. “CNC operators can set up the equipment to run on its own without supervision overnight. This ‘lights out’ capability means smaller shops can maximize their capacity without adding more staff.”

It starts with culture The mindset that a machining partner brings to precision aerospace machining is also critically important. “It starts with the culture of the shop and the problemsolving mindset they bring to a project – particularly for complex, precision parts,” explains Doan. “You also need a machining partner to be proactive. By engaging early in the process, an aerospace machine shop can anticipate and resolve machining issues before any parts are produced.” In a recent example, Halcyon had a customer bring them what appeared to be a simple part but could not find

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a machine shop that wanted to take the job. The part had a 6” threaded shaft with a hex head. There was an 832 thread across the outside diameter (OD) of the shaft. “Most lathes aren’t able to cut those threads across six inches,” said Doan. “We had to get creative since we could not use round stock, which is generally used when cutting OD threads.” The team determined how to form the threads while accounting for the “growth” that occurs when threads are formed on plate steel to meet the tight requirements. For it to run on a CNC machine, they also had to create a modified thread using a cut die to create a formed thread. “We took the challenge on and were able to meet the client’s deadlines with parts that met spec when no one else could do it,” said Doan. “It takes more than the equipment and know-how; it also means really having an appetite to take on these kinds of complex challenges.” Nimbleness and adaptability in precision machining represents a key consideration for aerospace clients as they seek partners to provide solutions to their complex design problems and production scale-up needs. Through cross-training, lights-out manufacturing and a problemsolving proactive mindset, smaller machine shops are well-equipped to meet the demand. For more information on precision aerospace machining, visit the Halcyon website at www.halcyonmfg.com or contact them at (408) 520-4655.

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On Exhibit - IMTS

ON EXHIBIT Industrial Machinery Digest's On Exhibit features the latest news and press releases from companies exhibiting at the leading trade shows across North America. WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com

SEPTEMBER 12-17, 2022 IMTS – The International Manufacturing Technology Show The largest and longest-running industry trade show in the Western Hemisphere, is held every other year at McCormick Place in Chicago, Illinois. IMTS 2022, which will run September 12-17, 2022, is where the creators, the builders, the sellers, and the drivers of manufacturing technology come to connect and be inspired. Industry professionals from around the globe will visit IMTS to discover the latest innovations in digital and traditional manufacturing, experience more than 15,000 new machining technologies, and find processes that will help solve their manufacturing challenges and improve efficiency.

LK Metrology, Inc to Exhibit New CMMs, Advanced Metrology Software and Related CMM Accessory Products at IMTS 2022 LK Metrology, Inc., a leading global designer and manufacturer of Coordinate Measuring Machines (CMMs), metrology software and associated CMM accessory products, will be exhibiting a variety of new products in Booth No. 135230 in the East Building, Level Three at McCormick Place in Chicago, IL for the 2022 IMTS Show…

HIWIN Features Torque Motor Rotary Tables at IMTS 2022 HIWIN Corporation, a leader in motion control and system technology, will feature families of precision motion control components this year at IMTS, with their Torque Motor Rotary Tables, (TMRT), as a highlight of their booth. IMTS will be held September 12-17, 2022, in Chicago. Designed for machine tool OEM’s and retrofitters, the TMRT series enables 3 axis machine tools to be readily upgraded to…

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www.imts.com

GF Machining Solutions Spotlights Precision and Productivity at IMTS 2022 At IMTS 2022 in Booth 338329, GF Machining Solutions will highlight advances in EDM technology, service, support, automation and tooling designed to help shops power through their unique manufacturing challenges with complete solutions and holistic support. Plus in booth 338376, System 3R will highlight tooling solutions to reduce setup time…

Greenerd To Highlight Innovative Hydraulic Press Solutions Including Automation, Custom Applications at IMTS Greenerd Press & Machine Company has announced it will be highlighting the company’s extensive hydraulic press and automation capabilities at IMTS Booth #236402 located in the Fabricating Pavilion, North Hall in McCormick Place, Chicago IL from Sept 12- 17, 2022. Application experts and design engineers…

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

GROB Systems to Demonstrate Challenging Aerospace, Medical and Mold 5-Axis Machining Applications at IMTS 2022 GROB Systems, Inc., a global leader in the development of manufacturing systems and machine tools, announced it will demonstrate a range of 5-Axis machining applications on its compact G350 Generation 2 Universal Machining Center at IMTS…

Norton Disc Grinding Wheels To Be Highlighted at IMTS Saint-Gobain Abrasives, one of the world’s largest abrasives manufacturers, will be highlighting its Norton Stellar Disc Grinding Wheels at IMTS Booth #237042 located in the Finishing/ Machining Pavilion, North Hall in McCormick Place, Chicago IL from Sept 1217, 2022. Norton Stellar inserted-nut grinding wheels for double and single disc grinding offer improved wheel life, increased parts per wheel…

Mazak Highlights Manufacturing Solutions for Every Shop at IMTS 2022 At IMTS 2022 in booth 338300, Mazak will show manufacturers how they can move their manufacturing operations forward with the company's latest innovations. Five pavilions will showcase solutions for job shops, advanced machining and high-production workflows. Among the 19 machines in the Mazak booth will be models from the company’s Ez, INTEGREX…

Suhner Offers Economaster® Drilling Units for Value-Priced Production Use Suhner introduces the ECONOmaster® line of drilling units, affordably priced at under $3500 for the basic unit, in stock for immediate delivery or customizable to suit the particular operation. This economical solution is ideal for multiple materials such as light metal, wood, composite, plastic and foam. Because these units are entirely produced at the Suhner factory…

Fastems to Exhibit its Innovative CNC Automation Solutions for High Mix Manufacturing at IMTS 2022 Booth 339186 Fastems LLC will showcase its CNC automation solutions for milling and turning machines at booth 339186 in the South Building at IMTS 2022. The highlight of the booth will be the world premiere of Flexible Pallet Tower FPT, a compact automation solution for APC and no-APC 4 and 5-axis machining centers with…

Open Mind Introduces New, Powerful Functionality in hyperMILL® 2022.1 CAD/CAM Software Suite Open Mind Technologies AG, a leading developer of CAD/CAM software solutions worldwide, has introduced its latest hyperMILL® 2022.1 CAD/CAM software suite which offers users new and enhanced features for even more powerful NC programming in applications ranging from 2.5D to 5-axis. “Continually improving…

Siemens to present digital-native CNC and more at IMTS 2022, booths 133346 and 433028 During IMTS 2022, Siemens will present its hardware automation and software technology portfolio, highlighted by the first-ever, digital-native CNC platform, SINUMERIK ONE, for machine tool applications. In addition, Siemens will present its solutions and services for the industrialization of additive manufacturing. In booths 133346 and 43302…

Absolute Machine Tools & Productive Robotics Lets IMTS Attendees “Free Play” with OB7 Line of Simple Easy-to-Teach Collaborative Robots Absolute Machine Tools together with Productive Robotics will exhibit their entire lineup of collaborative robots in booth #338519 in the South building at IMTS 2022. To give attendees a better understanding of just how easy it is to use and integrate these robots into their manufacturing processes,… INDUSTRIAL MACHINERY DIGEST.COM

IMD | 41

Product Showcase

PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers. WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

Universal Robots Adds All-New 20kg Industrial Cobot to Its Leading Portfolio Universal Robots, the Danish manufacturer of collaborative robots (cobots), has announced that it will add a new 20kg cobot to its product range. Called the UR20, the cobot boasts an all-new design based on Universal Robots’ experience in highly refined engineering and is the latest addition to the company’s strong portfolio of cobots. The UR20 is the best demonstration yet of Universal Robots’ unrivaled innovation in the cobot space, featuring an entirely new joint design that will allow for even faster cycle times as well as the ability to handle heavier loads.

The new SINUMERIK ONE CNC from Siemens becomes a digital-native machine tool control With SINUMERIK ONE, the first digital native CNC, Siemens is driving forward digital transformation in the machine tool industry. The new controller works with software to create the machine controller and the associated Digital Twin from one engineering system and thus contributes to the seamless integration of hardware and software…

ETEL’s New TBS Linear Axis Provides Precision and Stability to Semiconductor Manufacturing Equipment With the new TBS Linear Axis offering from ETEL, semiconductor equipment manufacturers can now integrate a high precision linear axis enabling outstanding performance in terms of accuracy and precision in its category of one-Degree-Of-Freedom (1-DOF) systems. With its ISO 2 rating for cleanrooms and incorporated…

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Siemens presents new innovations in direct robotic control at AUTOMATE 2022 The SINUMERIK Run MyRobot /Direct Control application allows machine tool users to integrate the mechanical robot model into the CNC for machine interaction and control. As a result, no additional robot controller is required. This direct control concept significantly simplifies the configuration of the controller hardware and optimizes the spare parts…

Extremely Compact ArcWorld Workcells Easily Integrate Robotics into Weld Processes The newest models of the ArcWorld® family of pre-engineered robotic arc welding workcells, the ArcWorld RS and ArcWorld HS, deliver a highly flexible, compact and cost-effective option for integrating robotics into current weld processes. Ideal for replacing or supplementing manual welding, such as pre-assembly before welding in larger robotic…

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

Siemens presents new software for Real-Time Locating System (RTLS) Siemens will present its new “Location Intelligence” software during AUTOMATE 2022, which expands the SIMATIC RTLS (Real-Time Locating System) locating platform to include the digital twin of performance. The web-based software analyzes and visualizes dynamic data, processes events, and can be addressed directly from local ERP (Enterprise Resource Planning)…

Custom Pneumatic Conveyors for Unique Applications EXAIR’s Line Vac Air Operated Conveyors provide an efficient method of converting ordinary pipe, hose or tubes into powerful in-line conveyors. To accommodate the wide variety of unique problems manufacturers face, EXAIR has the ability to customize and tailor Line Vacs to different specifications. Certain processes may require customizations like unique sizes, shapes and…

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eNET Monitoring & DNC releases eNET-Select, a web-based shop floor UI for Machine Monitoring & DNC system eNET Monitoring & DNC is pleased to announce the release of eNET-Select. This powerful add-on Machine Monitoring software is a customizable web-based touch screen UI that can be utilized on the shop floor to enter data for down-time reasons, ideal cycle rate, part number, operator, scrap parts for live…

Brass Fitting for Aerospace Applications from Guill Guill Tool, a growing supplier of components to the global aerospace industry, today announced the production of a new Brass Fitting. The Brass Fitting is made of C706 copper nickel alloy. Dimensions on this product are 1.875” outer diameter x 1.25” square each end X 5.40” overall length, or (47.625mm outer diameter x 31.75 square each end x 137.16 overall length).

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Hypertherm announces release of ProNest 2023 CAD/ CAM nesting software Hypertherm, a U.S. based manufacturer of industrial cutting systems and software, today announced a major version update to ProNest® 2023, its advanced CAD/CAM nesting software for automated cutting. This new release contains a collection of new features and on-going enhancements designed to help customers improve their operational efficiency while…

KHK USA Inc. announces Extensive Line of Inch Gears KHK USA Inc., distributor of the market leading KHK® brand of metric gears, announces its extensive line of inch gears. For over 80 years, Kohara Gear Industry has been known for their world class metric gear products. Recognizing the demand that still exists in the USA for diametral pitch spur gears, KHK USA is now offering made-to-order 4DP, 6DP, 8DP, and 10DP spit gears in both 20…

Jergens Inc. To Present Several New Workholding Solutions and Dedicated Custom Capability at IMTS Booth 432154 Jergens announces its first preview of several new workholding products that will be on display and demonstrated at this year’s IMTS, September 12 – 17 at Chicago’s McCormick Place in booth 432154. First among them will be additions to the company’s tooling columns made in the…

New cermet turning insert from Walter can double tool life and ensures maximum dimensional accuracy Walter has introduced a new cermet turning insert that delivers superior surface finish with reduced vibration. The new PVD coated cermet grade WEP10C, along with low cutting pressure from its negative clearance FP5 geometry and cutting-edge preparation, can boost productivity and dimensional stability in mass production. Primary application is steel…

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Electrical Box Retort Furnaces for De-Bindering Ceramic Composites L&L Special Furnace Co., Inc. has received an order for two atmosphere controlled retort box furnaces used for de-bindering ceramic composite matrix parts, (CMC) along with powder medals processing (PM) and hot isostatic processing (HIP). Initially CMC and other ceramic matrix components and additive manufactured parts…

READY GATE Adjustable Self-Closing Safety Gate OSHA and ANSI Standards require any surface above 48” (4 feet) to be guarded by guardrail systems. Any opening in the guardrail system must be protected by an offset rail or self-closing safety gate. The Model RG (Ready Gate) is an adjustable self-closing safety gate that meets the current requirements of OSHA 1910 Subpart D as well as ANSI-A1264.1-2017, and is …

ABB´s new Robotic Depalletizer solution reduces complexity in logistics while improving efficiency ABB has launched the ‘ABB Robotic Depalletizer’, a solution for handling complex depalletizing tasks in the logistics, e-commerce, healthcare, and consumer packaged goods industries. Using machine vision software, ABB’s new solution can quickly assess a wide variety of box types, enabling customers to efficiently process assorted loads with very…

Smith Metal Products Receives Federal Firearms License (FFL) Smith Metal Products has announced it has received the Federal Firearms License (FFL) and adds to its other accreditations that include ISO 13485, ITAR and ISO 9001:2015. This reinforces our quality commitment to producing components with unbeatable levels of precision, strength, and durability, at competitive prices” stated Jim Beyer, Sales Manager at Smith Metal Products. Smith Metal…

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IMD | 45

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ONLINE ONLY AUCTION SALE Surplus to the Ongoing Needs of GE Gas Power 2-Locations – Greenville, SC INSPECTION: BY APPOINTMENT ONLY FEATURING

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Advertiser Index Accudyne Products USA — www.accudyneproducts.com ...................................................... IBC Actek Manufacturing and Engineering Inc. — www.actekmfg.com ......................................... 33 AmCon Design & Contract Manufacturing Expo — www.amconshows.com .......................49 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com .................................... IFC Betenbender Manufacturing, Inc — www.betenbender.com .....................................................17 Burr King Mfg Co. — www.burrking.com ....................................................................................... 19 Carell Corporation — www.carellcorp.com ................................................................................... 13

SERVING AMERICAN MANUFACTURERS FOR OVER

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Clamprite — www.clamprite.com ....................................................................................................45 COXREELS — www.COXREELS.com ................................................................................................ 31 Denver Breaker & Supply — www.denverbreaker.com ...............................................................46 Design-2-Part Shows — www.d2p.com .........................................................................................48 Dynabrade, Inc. — www.dynabrade.com ................................................................................ 26, 27 Eagle Bending Machines — www.eaglebendingmachines.com ................................................ 13 ENM Co — www.enmco.com ...........................................................................................................49 Essex Structural Steel Co. — www.essexstructuralsteel.com .....................................................44 Federal Knife, Inc. — www.federalknife.com ................................................................................ BC Formdrill USA Inc. — www.formdrill-usa.com .............................................................................. 23 H&K Equipment, Inc. — www.hkequipment.com .........................................................................48 HMI div of Betenbender Manufacturing — www.betenbender.com ........................................43 Hypneumat, Inc — www.hypneumat.com ..................................................................................... 21 IMDauctions.com — www.IMDauctions.com ...............................................................................49 IMTS | International Manufacturing Technology Show (IMTS) — www.imts.com ................... 7 Industrial Magnetics, Inc. — www.magnetics.com ....................................................................... 37 Kanetec USA Corp — www.kanetec.com .......................................................................................44 KEC Incorporated — www.weldingequipment.com ....................................................................39 KHK-USA — www.khkgears.us .......................................................................................................... 35 Link Auctions — www.linkauctions.com ......................................................................................... 47 L&L Special Furnace Co., Inc. — www.llfurnace.com ..................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ........................43 Morgan Manufacturing, Inc. — www.MorganMfg.com ...............................................................49 Pro-Line — www.1proline.com .........................................................................................................49 Royal Products — www.mistcollectors.com ..................................................................................49 Schweiss Doors — www.schweissdoors.com ...............................................................................49 Scotchman Industries, Inc. — www.scotchman.com .................................................................... 9 Siemens Industry, Inc. — www.usa.siemens.com/cnc ................................................................FC Standard Direct — www.Standard-Direct.com .............................................................................48 Stor-Loc — www.storloc.com ............................................................................................................ 5 Suhner Industrial Products — www.suhner-machining.com ..................................................... 15 The Caldwell Group, Inc — www.caldwellinc.com ........................................................................ 3 Tormach — www.tormach.com........................................................................................................29 Trim-Lok — www.trimlok.com ...........................................................................................................11

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