» Additive Manufacturing: A Solution that Continues to Emerge for Small- to-Medium Size Manufacturers What do small-to-medium size manufacturers have to gain from embracing additive manufacturing, and what obstacles are in their way? » Q&A with Lubrication Engineers » The Do's And Don'ts of Performing Time And Motion Studies » The Future of Additive Manufacturing: Advantages and Strategic Implications » Q&A with 3M’s Mike Vale » What Is an Automation-Enhanced Workforce? » Optimizing Forging Machine Productivity and Longevity CONTACT US FOR A FREE NO-OBLIGATION DEMONSTRATIONDYNABRADETODAY! ABRASIVE BELT TOOLS “ The Original” Dynafile® Dynafile® II Pipe Belt FinisherDynafile® III Quickly grind and remove welds, deburr rough edges, and polish hard-to-reach areas. Dynabrade quality American made tools are precision designed and manufactured, allowing for fast and efficient production with less rework. Dynabrade_IMD_FrontCover_Sept2022.indd 1 8/24/22 11:38 AM IndustrialMachineryDigest.com | September 2022 North America’s Manufacturing Resource for Industry Professionals Since 1986
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Find out why time studies remain a critical method of data collecting in plant settings, as well as the do’s and don’ts of conducting and analyzing time and motion studies, in this article.
Additive manufacturing is a tool that offers several benefits when successfully adopted by small-to-medium size manufacturers, but it’s often a long journey. Learn more about this focus topic in our manufacturing showcase! WOrKFOrCe DeVeLOpmeNt Could targeted automation and specifically flexible automation be a way to bridge or even close the workforce skills gap? Find out in this installment of “Safety & maintenance!” NeW AlstomteCHisworking together with replique’s on-demand additive manufacturing platform to produce customized industrial-grade serial parts in order to digitize its supply chain and produce small batches on demand and decentrally.
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ColUMns 12 bUSINeSS 4.0 the Future of andmanufacturing:AdditiveAdvantagesStrategicImplications By Dr. oec. HSG Dr. phil. Jörn Lengsfeld 16 tALKING SHOp 3m — mike Vale President of 3M’s Safety & Industrial Business Group 20 SAFet Y & mAINteNANCe Optimizing Forging machine productivity and Longevity By Del Williams DePaRTMenTs 6 eDItOrIAL DIreC tIONS 8 INDUS trY NeWS 40 ON e XHIbIt 44 prODUC t SHOWCASe 47 SUrpLUS bUYING & SeLLING 49 CLASSIFIeDS 50 ADVertISer INDe X on THe CoVeR Cover Sponsor: Dynabrade. photo: Courtesy of 3m
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4 | IMD September 2022 Table of ConTenTs feaTURes 22
JoinprOCeSSourconversation with paul Grimes and Clay Calk from Lubrication engineers to find out what made this industry leader a "a one-stop shop for lubrication reliability,” as well as what’s in store for this company’s future. INDUS trY INSIGHtS
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William C. Strickland III, Publisher
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I’m excited to bring you another riveting and educational content-packed edition of our magazine. the focus topic for this issue is, “what does additive manufacturing mean for small- to medium-sized manufacturers?” And we have certainly answered that question and more throughout this edition.
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INDUSTRIAL MACHINERY DIGEST (ISSN 1542-5223) is published 12x per year by Source 360 Media. POSTMASTER: Please send change of address to INDUSTRIAL MACHINERY DIGEST, 3590-B US Hwy 31 South, PMB 233, Pelham, AL 35124. Printed in the U.S.A. SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the U.S. to qualified individ uals. Publisher reserves the right to reject nonqualified subscribers. Oneyear subscription to nonqualified individuals in the United States: $9600. Single copies available (prepaid only) $2000 each.
I’m so glad you’re here, and hope that your fall is off to a good start.
In “manufacturing Showcase,” you’ll find a comprehensive, in-depth look into what additive manufacturing — aka 3D printing — looks like on smaller scales for small- and mediumsized manufacturers, as well as answers to important questions like: is this technology still emerging, and how can these smaller key industry players embrace it and leverage it with their traditional manufacturing methods?
We’re also featuring an interview with rick blake, the founder and president of edgewater Automation and an industry veteran with 40 years of experience in custom automation. this company is a great one to profile on the topic of 3D printing, as they use it every day in a myriad of ways, including to prove their tooling, make sample parts to help develop processes, and — in some cases — to 3D-print parts for machines when other methods are either impossible, improbable, or too expensive.
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In our “ talking Shop” Q&A, you’ll find a conversation with mike Vale, the president of 3m’s Safety & Industrial business Group, where we discuss the company’s outstanding corporate culture that cultivates diversity and innovation. Additionally, you’ll find an in-depth look into what the concept and application of an automation-enhanced workforce looks like for the American manufacturing industry. Is it feasible? We’ll let you decide. Lastly, I want to encourage you — our readers — to reach out to me directly and let me know what you want to read about in this publication and on IndustrialmachineryDigest. com. this magazine is custom-made for you and your customer base, so we need your feedback to tailor your needs and the needs of the industry via written educational content.
Or, even if you just want to say hi or make plans to meet up at an upcoming industry event, drop me a line at achoward@ industrialmachinerydigest.com.Asalways,thanksforreading, and I hope you have a spectacular September! Editor, Industrial Machinery Digest achoward@indmacdig.comhttps://bit.ly/ACHLinkedIn
Welcome to the September 2022 issue of Industrial machinery Digest!
6 | IMD September 2022 eDiToRial DiReCTions
THE STANDARD EYEBOLT REDESIGNED. The VRS-STARPOINT allows alignement of the eye, prior to lifting into the load force direction. This excludes dangerous untightening (like common, rigid eybolts). Thanks to high-strength quenched and tempered steel and ICE-Bolts, this modern lifting point allows a 4 to 5 times higher WLL, or downsizing of the needed thread dimension (approx. half of the diameter size) compared to a common, standard eyebolt.
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Jamen has been with edgewater since he was in high school, working summers, then full-time after graduating Hope College in 2012 with a degree in business management. Jamen was part of the six-person start-up team in 2013 at edgewater’s second automation facility in Spartanburg, SC; first as purchaser, setting up the supplier network, then as applications engineer, creating 3D machine simulations and then building growth as marketing manager, before moving into a project management role. When Jamen joined the automation facility in buchanan as project manager in 2021, the Spartanburg facility had grown to 70 employees. “I look forward to using my start-up experience to help take buchanan to the next level, working with our other divisions to balance workloads and leverage strengths to grow together as one company,” Jamen says. “We want to carve out a world-class automation facility here in buchanan, and we’re going to work hard for it.”
www.IndustrialMachineryDigest.com Streamlining Credential Processes Bringing Global Technology to a Local LevelManufacturing IndustrialMachineryDigest.com October2021 MANUFACTURING SHOWCASE: FEATURED Cincinnati,STORIES: Inc. IMPACTINGDROPZONE Wildeck Provides Increased Safety for Moving Palletized Loads the » Empowering Employees » Surpassing Energy Savings Manufacturer in Oxnard, CA experiences the benefits of Green Hydraulic Power Units » Lifting Higher Combi-PPT - A High Capacity Powered Pallet Truck Streamlining Control Siemens Offers Optimized Control Panel Construction to Machine Tool Builders IndustrialMachineryDigest.com March 2019 IndustrialMachineryDigest.com June2021 ESTABLISHED IN 1986 AND IS THE INDUSTRY’SMost Extensive IndustrialPublication. GETTING BACK TO WORK!! 2021 INDUSTRIAL MACHINERY DIGEST’S NEWSINDUSTRY
Exact SharesMetrologyInnovative 3D Scanning Technologies & Scanning with Area Industries exact metrology: A Division of In-place machining Company, a comprehensive 3D metrology service provider and hardware sales company, recently hosted technology Fairs at their facilities in brookfield, Wisconsin and moline, Illinois. each event drew over 100 people from the surrounding areas who were interested in learning more about the industrial benefits of innovative and highly accurate 3-dimensional scanning technologies and software. Attendees included quality assurance and quality control engineers, manufacturing and production personnel, and other supervisors and technicians from a variety of industries including power generation, automotive, off-highway, consumer durables, and others.
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New Leadership at Edgewater Automation in Buchanan edgewater Automation, a global custom automation equipment supplier, named Jamen blake managing Director at their recently opened (2019) automation facility in buchanan, mI.
8 | IMD September 2022
Jamen’s predecessor, Kevin moynihan, continues with edgewater Automation leading contract manufacturing and assembly. “Kevin is positioning us for exponential growth through collaboration with our exceptional team at the edgewater manufacturing Division in buchanan,” says edgewater president rick blake. “ this is a great time for Kevin and Jamen to be in their respective roles as we integrate more and more innovation into our machine design and build.” For more information on edgewater Automation, see our interview with rick blake, founder and CeO of edgewater Automation.
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EXAIR Offers Case Study Library for Detailed Examples of Successful Solutions e XAIr .com offers a great number of resources for better understanding how products will work within a given process. Among those is the e XAIr Case Study Library with Digest's industry news features the latest news releases from some of the industry's top companies. Send your press releases to editorial@indmacdig.com
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INDUS tr IA L MACHINERY DIG e S t COm IMD | 9 PROUD AMERICAN MANUFACTURER EST. 1967 PROUD AMERICAN MANUFACTURER EST. 1967 POWERofthree • American Made Ironworkers 45 to 150 Ton Models • Top Notch Support & Local Service • 3 Year Warranty Convenient & Free. We bring Scotchman machinery to your location. See them in action & test cut your material without leaving your place of business, anywhere in the lower 48. Scan QR Code or Call (800) 843-8844 www.scotchman.com Scotchman IMD Half Page Ads 2022.indd 2 4/8/22 11:45 AM over 40 detailed and downloadable accounts of how e XAIr products have improved a customer’s process. Whether searching by product line or application, get a full breakdown on the problems the specific subject was facing, and how e XAIr’s intelligently engineered products improved the process following their installation. Replique Creates Network of Material Partners to Advance Industrial 3D Printed Parts Production replique, part of the internal venture builder of bASF and the creator of a digital distributed manufacturing platform that enables Oems to provide spare parts on-demand, has announced the creation of a partner network of authorized materials vendors. the move represents an important step in the company’s objective to make its 3D printing platform accessible to more Oems and provide best-in-class and tailored materials to industrial customers.
CERATIZIT USA Moves Headquarters to centralize operations and continue to better serve its customers, tooling supplier Cer AtIZIt USA, Inc. has shifted its official U.S. Headquarters from Warren, michigan, to the company’s Schaumburg, Illinois, facility location. Cer AtIZIt acquired the Schaumburg facility when it absorbed the KOmet tooling brand name and product line under the Cer AtIZIt Group umbrella.
Importantly, the partner network, which initially comprises LeHVOSS Group, evonik Industries, Forward Am, and igus GmbH, will ensure that the required standards pertaining to the development, manufacture, and certification of advanced materials are met in order to qualify industrial production in 3D printing of spare parts. As part of an automated quality documentation process, a certificate of analysis, stating that the supplied materials meet the required specifications, is provided and linked to each part, and then saved on replique’s digital inventory platform.
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Cer AtIZIt USA offers a full-range product portfolio that spans 65,000 tooling products specifically focused
Inner Geometry Data Provided by Timken in KISSsoft KISSsoft and timken have teamed up to add more value for design engineers. bearing calculations from timken can now be easily generated in KISSsoft for the software’s registered users. Although the data is not visible in KISSsoft, it can be used in the background for calculation and design purposes. In the KISSsoft release 2022, t imken is now providing internal macro geometry for more than 7,000 t imken® tapered, spherical, cylindrical roller, and deep groove ball bearings. t his allows KISSsoft users to perform more accurate ISO t S 16281 life calculations, giving them more confidence when designing and specifying bearings for their equipment. t he inner geometry data for the rolling bearings in use is retrieved via t imken's cloud serviceWantsolution.tolearn more about how to access and use timken data in KISSsoft? Visit www.kisssoft.com/en.
10 | IMD September 2022 on the needs of U.S. manufacturers. Under the name team Cutting tools, the portfolio includes solutions from Cer AtIZIt as well as tooling under the KOmet, WNt, and KLeNK brand names. Cer AtIZIt USA engineers and manufactures highly specialized, precision cutting tools for drilling, boring, reaming, milling, and turning.
Women in Manufacturing Association Announces HERizon 5K Race to Support Training and Education Opportunities for Women in Industry t he Women in m anufacturing® (Wi m) Association’s 12th annual SU mm I t, October 10-12, 2022, in Atlanta, GA, will open on October 9 with the inaugural H erizon 5K race in support of the Women in m anufacturing education Foundation (Wi meF). t his public event serves an important role in helping Wi m fulfill its mission to provide ongoing programs and cultivate new initiatives to assist women in the manufacturing industry gain knowledge and become leaders within their companies and Sincecommunities.itsinception in 2016, the WimeF has impacted thousands of women with its programming, including 14,000 professionals who have participated in the foundation’s monthly Virtual Learning Series and more than 300 women who have graduated from formal leadership programs—the management Development program and the Leadership Institute for Women in S tem and manufacturing.theHerizon5K will take place on Sunday, October 9, 2022, at 2 p.m., leading racers on an exhilarating route through midtown Atlanta, GA. t he registration cost is $45 and includes a logoed t-shirt and celebration beverage at Stats b rewpub. Awards will be presented to the top 10 finishers as well as the top individual and team fundraisers.
MassRobotics, Festo, Mitsubishi Electric Automation, MITRE, and Novanta Join Efforts to Support Healthcare Robotics Startups massrobotics, Festo, mitsubishi electric Automation, mItre, and Novanta are calling on startups in the healthcare robotics space to apply to the second Healthcare robotics Startup Catalyst program. the objective of the program is to advance healthcare robotics companies by providing the connections, guidance, and resources they need to grow and succeed. the selected startups will be guided by seniorlevel mentors from organizing companies and supported to connect with potential customers, investors, suppliers, marketing, and more. Additionally, the selected startups will exchange milestones with the larger Healthcare robotics Working Group, comprised of an eastern U.S. cluster of corporate, academic, government, startup, and venture capital volunteers. the program focuses on startups in the areas of clinical care, public safety, laboratory, supply chain automation, out-of-hospital care, and quality of life. It also addresses continuity of work and education, as well as training and support for healthcare professionals.
manufacturing is an umbrella term for a whole new archetype of production. It describes a wide variety of production technologies. these differ in the type of raw material used, the approach to successive joining, and the technologies to steer the process. the common characteristic of all of those is the Conjunctive emergence of objects from raw material according to a specified design. that’s why this new archetype of production is often contrasted to Subtractive manufacturing, where material is taken away to shape the product, for example by hewing, carving, cutting, drilling, milling, filing, and grinding. In contrast, in additive manufacturing Conjunctive emergence is achieved by technologies like material Jetting, material extrusion, binder
ABOUT THE AUTHOR Dr. oec. HSG Dr. phil. Jörn Lengsfeld is a German economist, management expert and communication scientist. He holds research doctorates from the University of St. Gallen (doctor oeconomiae) and the philosophical Faculty of the University of erfurt (doctor philosophiae). Learn more about him and his work on his website, joernlengsfeld.com, or contact him at mail@joernlengsfeld.com.
The Future of ImplicationsandAdvantagesManufacturing:AdditiveStrategic
A dditive manufacturing is a novel archetype of production technology. It alters the very nature of the production process itself. Its rise is tantamount to a paradigm shift. What is additive manufacturing? What are its advantages, and what are the implications on business strategy? What is Additive Manufacturing? Additive manufacturing is the creation of physical three-dimensional objects by successively joining raw material into a well-specified shape, usually by sequential layering and bonding which is controlled by digital technologies. Colloquially, additive manufacturing is often referred to as 3D-printing. technically that is not entirely accurate, because printing is just one of its forms. rather, additive
12 | IMD September 2022 bUsiness 4.0 Dr. oec. HSG Dr. phil. Jörn Lengsfeld
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As an all-round optimizer, additive manufacturing helps in all phases of product optimization: design, production, and improvement. In design, for example, geometric freedom allows components to be optimized for static stability, material use, and weight saving. the production
Jetting, powder bed Fusion, Directed energy Deposition, Sheet Lamination, and Vat polymerization. With those technologies it is possible to process a wide variety of raw materials. Well established is the use of plastics, polymers, metal and ceramics. but today the spectrum is much wider, extending to materials as diverse as concrete and biological tissue. And further materials are explored in research and development.
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Conjunctive emergence has been a dream of humankind, one as old as time. the ability to conjure physical objects out of amorphous material is a notion dating back to ancient legends, an idea that had been attributed to the realms of magic. Now technology has turned magic into reality. Fascinating in itself as it may be, it also bears very substantial advantages. the following overview pointedly details some general advantages that may in principle occur with additive manufacturing. Of course, they do not necessarily manifest in every scenario, and of course there are also disadvantages that have to be taken into account. However, this article is not about individual applications but the general features of this new archetype of technology and the resulting potential to induce transformational change.
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Geometric Freedom the limits of technology are the limits of design – this has always been a fundamental truth of traditional manufacturing. particularly, in regard to the geometric shape of the product. this restriction is almost entirely lifted by additive manufacturing. Conjunctive emergence offers geometric freedom. Almost any shape is possible. Forms that could not be created in any other way. this freedom of design comes with the most wonderful of consequences: Allowing new aesthetics. enabling new physical properties. Facilitating new mechanical characteristics. engineering new ways of construction. Ultimately, leading to new products, serving needs hitherto impossible to fulfill. Just thinking about healthcare, for example, this is spectacular news.
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Simplification by enabling complexity – geometric freedom has an astonishing impact on product complexity: Allowing the fabrication of more complex parts can result in end products that are more sophisticated yet less complex. With additive manufacturing it is possible to create objects in one piece that would have required assembly of multiple parts otherwise. A work step saved. Quality potentially increased. And it gets even better. 3D-printers are indifferent as to what shape they print. Complexity is free, after all.
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Product Complexity
process itself is inherently waste-reducing, as in additive manufacturing only material needed is being used. this is in sharp contrast to Subtractive manufacturing, which is all about removing excess material, necessarily resulting in waste. And, finally, additive manufacturing is predestined to facilitate incremental improvements: With no product specific hardware required, there is no upfront investment which makes it possible to include any improvement directly into the ongoing production. Conjunctive emergence allows for Iterative Innovation. Welcome to the world of agile manufacturing!
Precise Reproducibility
Fixed Cost Effects
once C-FRAME PRESSES HYDRAULIC MACHINES OF IOWA A
• Press Bed bolted on, not welded, to prevent distortion.
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Consistency is key, when it comes to quality. And screwing this up gets more likely by the numbers: the number of parts, the number of work steps, and the number of people involved. Additive manufacturing can help to reduce all of them. And in the production process itself it offers precise reproducibility due to computer control, full automation, and the homogeneity of the raw material. best of all: reproducibility is an inherent characteristic of additive manufacturing, coming without further cost. remember that quality consistency is free.
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Product Optimization
Advantages of Additive Manufacturing
14 | IMD September 2022 a choice is made, whether it’s in regard to a product, a business model, or a strategy. t hat’s why it is most relevant that additive manufacturing has effects on fixed costs. In principle, besides the 3D-p rinter, no further hardware is required. No product specific setup. No mold. No tools. No equipment. t his has huge implications. m ost importantly, no product specific upfront investment in hardware is required. Idea, design, and plan are the only product specific upfront costs. Furthermore, without the need for a specific setup, there are no setup times. And no specific training is necessary that would be time consuming. m arginalizing initial fixed costs of a product, all this paves the way for instant break-even, which is the precondition for single-piece production and small batches. With conjunctive emergence, it makes no difference in the cost of production itself whether two identical pieces are produced or two variants.
Variety is free! Process Simplification
Contra-intuitive as it may sound, a technology as complex as Conjunctive emergence can result in process simplification. Unitary one-step production simplifies organization, diminishes the need for coordination, reduces product complexity, eliminates compatibility issues, and abolishes the need for assembly. Simplification is enhanced further by digitalization. the production process itself is steered by software. All of this has also an impact on the competence level required: process management capability and craftsmanship are less important. that is why some use the moniker of little-skill manufacturing –inappropriately, of course, as the skills required in design and handling are advanced. Digital Native Additive manufacturing is the digital native among production technologies. All technologies of Conjunctive emergence are founded on software control. None of them could work without it. While other archetypes of manufacturing need to be digitalized, Conjunctive emergence is inherently digital. And often it enables unitary one-step production. both featured combined allow for a seamless integration into a fully digitalized production chain. From dream to data to 3D. Additive manufacturing can serve as an interface between the Digital Infosphere to the physical entisphere. It’s does something unique: materialize information. this is a most sought-after feature in a digital economy. Strategic Implications Anyone can be quick to conclude the obvious. tragically, too many leave it at that. Let’s not be one of them. this is always good advice. but in regard to the business implications of additive manufacturing it seems necessaryAdditiveadvice.manufacturing is clearly a most flexible production tool, ideally allowing a lot size of one without
upfront cost, fully integrated in the digital workflow. As such it is perfectly suited for prototyping, which was one of its early applications (rapid prototyping). It is also optimal for spare parts of outdated products, helping with inventory efficiency, logistics, and time to repair (rapid repair). And it is perfect for individual production, that traditionally involved a lot of manual craftsmanship. A typical example is dental prosthesis production. Also mechanical engineering and plant construction is a classical use case (rapid tooling). All of those applications are, well, obvious. One should not halt at this conclusion. the colorful bouquet of advantages presented above suggests that they have the potential to unfold implications of greater strategic reach. What are they? With product-specific fixed cost crushing, break-even shortening and process simplification, traditional entry barriers diminish. With variety becoming free, individualization and mass customization mature into the new normal. With reproducibility, main pillars of competitive advantage break away, like production technology leadership, process perfection, and skill; what really remains is intellectual property rights. With new forms of product optimization, a shift toward agile manufacturing is on the verge. Combined, these trends have the potential to fundamentally reconfigure the competitive landscape. Lower entry barriers entice new players to the market. process simplification gives smaller companies a chance. And individualization induces a paradigm shift from economies of scale to adaptability. beside these changes driven by process innovation, also product innovation is likely to occur. With geometric freedom, freedom of design, and free product complexity the creation of completely new products is possible. thinking of end-products there will be substitutes, surrogates, and completely new products serving hitherto unaddressed needs. but there will be also new components for existing end-products. And finally, the rise of additive manufacturing is part of the larger trend of Digital transformation, which changes the structures and the functional logic of the economy drastically. Digital transformation reshapes the very foundations of the economy and additive manufacturing is both, a driver of this development as well as an ideal fit for the structures of this new world. What is the quintessence? Wrapping it up, we observe a combination of process innovation, product innovation, and business model innovation. In combination, they have the potential to alter the functional logic of the industry significantly. t he success drivers are likely to shift from economies of scale to adaptability and from perfection of production processes to optimal integration into the value chain in the Digital e ra. Amid such revolutionary transformation, many may wonder if there is anything constant to provide guidance. Ultimately one truth always prevails — economy is about satisfying human needs. Find ways to do that, and you are in business.
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According to 3M’s State of Science Index, 90% of Americans agree there’s a lot of opportunity for jobs in skilled trades. However, while 71% say they respect people who pursue skilled trades, those same people would not pursue one themselves. Why do you think this is? And why is it vital to work toward changing the perception of what this skilled labor means to attract a new, modern workforce? When nearly three-quarters of Americans say they wouldn’t pursue a career in the field although they respect people who do, it appears the trades have an image problem. 3m sees this as a major barrier to replenishing the skilled trade talent pipeline. there are many pervasive misperceptions about skilled trades – from the type of person who should pursue a trade to the jobs that qualify as trade careers and whether you can make a decent living. On a positive note, 3m’s 2022 3m State of Science Index – an annual global research study exploring trust in science and its relevance to everyday
TalkinfeaTURinG:GsHoP
Among our people, we offer diverse opportunities for continued education and enrichment, from ongoing training and certifications to resources for language learning and skills development. beyond our walls, we are working to help younger generations receive adequate training and opportunities through education. In 2021 we set a global, educationfocused goal to create five million unique S tem and skilled trades learning experiences for underrepresented individuals by the end of 2025 – which includes scholarships, internships, and robust student services, varying experiential learning opportunities, monetary investments, and volunteerism.
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Could you describe the “3M culture” and what its current perception is as it pertains to workforce development and trade skills?
How are mentorships established within 3M, and how does this program support mentees once the mentorship is completed?
3m works with schools, universities, community colleges, and trade schools, and other community organizations around the world to encourage students to pursue a S tem or skilled trade career, while also increasing their access to the tools, resources, and knowledge they’ll need to succeed. For example, our 3m manufacturing and Academic partnerships (mAp) program introduces students to careers in manufacturing. We started this program when we noticed a significant shortage of skilled trade workers primed and ready to fill roles that were being vacated by those retiring from their careers – and that’s something we’re committed to changing. mAp connects students to careers in manufacturing through grants that support robust mechatronics curriculum, as well as 3m employees as guestAdditionally,educators. our 3m techtalks program brings 3m volunteers into classrooms to provide students with the opportunity to meet and interact with role models who enjoy technical careers. through these and other ongoing programs, we hope to further develop the skilled trade talent pipeline and show younger generations that these careers – and success – are relatable and attainable.
Our 15% Culture program has been an integral part of 3M’s innovation process for decades, and it’s a core element of our work environment.
At 3m , we know our employees want to grow and access development opportunities – and we want the same for people around the world.
TALKING SHOP WITH: Mike Vale — President of 3M’s Safety & Industrial Business Group
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We’ve collaborated with middle and high schools in both Austin, texas, and the twin Cities in minnesota to provide information on trade careers and schools. We know students start to form an “occupational identity” – thinking about what’s possible for them to do as a career – as early as middle school, so it’s important we start to raise awareness and focus education at that level.
» A commitment to helping employees find at least one hour per week to learn, with supervisors encouraging them to block time on their calendar.
Within 3m , we offer several programs for employee growth and development, including:
» thousands of on-demand courses that employees can access any time, recommended courses and training, informal and formal mentorship programs, and a tuition reimbursement program. We also offer the performance everyday program, which empowers 3mers to think about their career performance beyond mid-year and year-end through transparent, frequent conversations. It creates a continuous feedback culture through one-on-one discussions between managers and employees to fuel meaning and purpose in everyday work, improve performance, discuss development, adjust priorities, learn from feedback, share recognition, and celebrate results.
Part of your drive toward innovation involves the “15 percent rule.” Could you expand on that?
» A team of learning partners for our business groups and functions to connect learning needs to learning opportunities. We’re also working to provide personalized Learning tracks that meet employees where they are and help them grow.
According to our 3m State of Science Index, Americans are expecting their employers to provide upskilling support and opportunities – including financial support or reimbursement. more so, as younger generations continue to see the impact that digitalization is having on their everyday lives, they understand that digital skills will only help them to grow their careers and expect to be increasingly reliant on digital skills in the years to come.
What does “upskilling” mean to you, and what is 3M doing in this area as it relates to encouraging people to pursue science and industry? Upskilling means taking the skills you already possess to the next level through additional education and training. It is an important part of career development and growth –especially as more people desire to keep up in a job market that is becoming increasingly dependent on digital skills.
Our 15% Culture program has been an integral part of 3m’s innovation process for decades, and it’s a core element of our work environment. rooted in the pursuit of scientific exploration and cultivating creative ideas, this program encourages employees to spend 15% of their work time pursuing innovative ideas – regardless of how it relates to their current role. While it is also important to ensure day-to-day responsibilities are executed upon, allowing employees the space to try something new, think creatively, and challenge the status quo gives them the freedom to innovate and solve meaningful problems.
18 | IMD September 2022 lives – found that nearly all Americans (94%) believe the workforce needs more skilled trade workers. the survey also showed that 90% agree there is a lot of opportunity in skilled trades, and 77% believe they would earn as much money in a skilled trade as they would in a career that requires a four-year degree from a traditional four-year university or college –further validation that trades can provide many promising, and profitable, career opportunities. to misperceptionscombat around skilled trades, the many educational and career paths available need to be highlighted and young students need to be supported in their pursuit of a trade education. For example, 3m’s Safety & Industrial business Group is committed to raising awareness of skilled trades as a viable career. We want to help solve the skilled trade labor shortages our customers are facing, while also building equity in our communities (black Americans and U.S. Hispanics continue to be underrepresented in the trades).
How are diversity and inclusion achieved at 3M?
ABOUT THE INTERVIEWEE
INDUS tr IA L MACHINERY DIG e S t COm IMD | 19
While 15% Culture has a long and fruitful association with our laboratory and technical employees, 3mers from all roles can take advantage of it. t his is one of the strengths of our company and an integral part of the culture that makes us unique. It is a tradition that speaks to the value our leadership places on innovation, idea sharing and the value of curiosity.
mike Vale is the president of 3m’s Safety & Industrial business Group, which includes personal safety, adhesives and tapes, abrasives, closure and masking systems, electrical markets, automotive aftermarket, and roofing granules. He was most recently head of 3m’s Health Care business Group, and prior to that led the company’s Consumer business Group. mike joined 3m in 1992 and over the years, his career with the company has sent him abroad four times for varied roles, including research chemist, manufacturing director, and general manager. mike serves as a member of the board of directors of the toro Company and is a former trustee of the Science museum of minnesota. He can also be found running, antiquing, reading science fiction, and spending time with his family.
Diversity is a competitive advantage for 3m that’s why we’ve made ambitious commitments across our company to advance diversity, equity, and inclusion in our workplaces, business practices, and communities. We are proud of our culture of belonging at 3m – having all our employees thrive by feeling valued, respected, and heard for their unique perspectives. We have a community of nine employee resource Networks – employee-led groups that champion diversity and the life experiences of underrepresented employees at 3m they give 3mers the opportunity to focus on leadership development, collaboration, and community service. 3m builds our equity goals directly into our business practices. In 2021, our four global business groups established goals that would use their unique capabilities and resources to advance equity in our communities. the company is implementing strategies to double our supplier spend year-over-year with women- and minority-owned businesses, and among its many initiatives, 3mgives (3m’s community investment arm) is investing $50 million over a five-year period to address racial opportunity gaps through workforce development initiatives.
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Diversity and inclusion are key values at 3m and vital to helping us build a healthy, creative, and respectful culture where all voices are valued and heard. As a global company, we strive to represent the diversity of our customers, suppliers, and communities. this means supporting leaders who are diverse across a wide spectrum of dimensions including gender, nationality, race/ethnicity, disability, U.S. military veterans, and LGbtQI+.
Del Williams ABOUT THE AUTHOR Del Williams is a technical writer based in torrance, California, and has contributed multiple articles to Industrial machinery Digest on such topics as manufacturing best practices, safety methods, preventative maintenance, surface grinding technology, CmmS strategies, and more.
20 | IMD September 2022 safe T y & MainTenanCe
LongevityProductivityForgingOptimizingMachineand
forging equipment oeM delivered “health check,” and ongoing preventive maintenance program helps forgers optimize production and keep equipment online even when faced with high turnover. A s the forging industry’s most experienced maintenance staff and equipment operators retire, keeping legacy machines producing at full capacity is increasingly difficult. When new employees lack sufficient expertise, and decades-old forging equipment breaks down, the result can be very costly, extended downtime.
“A seasoned team may know all the ‘ins and outs’ of every forging machine in a facility, but when workers leave, or retire, the preventive maintenance can suffer and equipment like hydraulic presses eventually will begin to break down,” says Jay raygor, Service Supervisor at Ajax-CeCO-erie press. “When that happens, the cost of hourly downtime can be several thousand dollars per hour.” raygor adds that although some customers follow routine maintenance guidelines, most keep producing products until the equipment breaks down. “ the danger with this approach is that the lead time for some major component parts can be 20 to 26 weeks,” he says. As a solution, industry-leading Oems like Ajax-CeCO-erie press (ACe) are now providing forgers with a proactive “health check,” followed by an ongoing preventive maintenance (pm) program designed to sustain peak performance of equipment that may be many decades old.
ACe is the largest forging equipment supplier in North America. With its core brands founded in the 1800s, the company offers a full line of products, including standard mechanical forging presses, upset forging machines, forging rolls, hydraulic forging, forming, compression molding, cold extrusion, compaction, roll ring preform presses along with stretch forming and straightening machines, solid
Time for a Health Check
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For more information, visit www.Ajaxerie.com.
“Consumable items common to every forging machine, like friction plates and driving plates for presses and upsetters, or piston heads, rods, rings, and packings for hammers, are often stocked. However, it is even more important to stock key items such as main gears, eccentric shafts, and rams to avoid long lead times for replacement,” says raygor.
INDUS tr IA L MACHINERY DIG e S t COm IMD | 21 IMD – North America’s Manufacturing Resource for Industry Professionals
MANIFOLDS…CIRCUIT-BLOCK
He notes that in the stocking program, the customer pays a percentage of the cost and then the balance when they take possession of the part – even if 2-3 years later. A custom stocking program with minimal up-front investment can eliminate months of downtime due to long lead time parts. to ensure the performance, consistency, and reliability of forging equipment, routine inspection, and preventive maintenance have always been essential. When forgers find this increasingly taxing as their most experienced technicians retire, opting for periodic health checks and preventive maintenance with industry experts can be crucial to long-term productivity and quality.
die forgers, trim presses, programmable die forgers, and custom-engineered hydraulic presses.
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Although pm is typically performed onsite, some actions can be performed remotely. ACe can utilize advanced collaboration tools and real-time video
As human beings age, the need for more frequent health checks is required to catch minor issues before they become serious. the same is true with forging equipment such as hydraulic presses, particularly if used for many“Somedecades.olderforging machines have been in service since the 1950s and 60s, so there are legacy parts that may be obsolete. On these older machines, operators may not know how to troubleshoot an issue or even identify a worn or failing part. this increases the risk of a major breakdown,” says raygor. the challenge only intensifies when there is a variety of forging equipment types and brands on the same production floor. For this reason, ACe offers forgers a comprehensive program of routine health checks on many major brands including Ajax, Chambersburg, erIe press, and L&F (formerly Sheridan-Gray). to perform a health check, ACe utilizes the full documentation of the equipment in its broad portfolio of brands, along with extensive maintenance and repair experience accumulated over many decades. the company’s technicians examine the equipment condition, running clearance, electrical system, pump performance, etc. based on the results of the health check, the Oem then suggests corrective actions to restore the equipment back to Oem specifications, along with a customized, ongoing, preventive maintenance program for hydraulic presses, along with consumables like filters, and oil sample analysis. the extent of the pm program is based on factors such as the type of equipment, production, onsite support, and desired pm intervals. It can be scaled up or down to take into account the maintenance team’s experience, availability, and turnover. “We want to be able to fill in where the customer’s needs are,” says raygor. the program can serve as a teaching aid to help the forger build its maintenance team. this can not only increase the team’s self-reliance, but also minimize any downtime. “ the maintenance team can shadow and assist us, and we explain what we are doing, why we are doing it, and how to proceed. Over time, they will increasingly be able to maintain the equipment themselves,” says raygor. He points to an example of one forger that dramatically improved its own in-house pm capability with such a learning process.
“A customer that had one of our presses did not have much of a maintenance program due to significant turnover. So, we visited annually for years, and each time walked employees through the process. recently, when we visited, we couldn’t believe how good their pm had become,” says raygor.
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communications to connect with technicians where both can see, discuss, annotate, and resolve many situations at hand. to ensure the highest production uptime of forging equipment, and prevent lengthy unexpected downtime, ACe offers a separate stocking program as an option.
DESIGNERS AND BUILDERS OF HYDRAULIC PRODUCTS AND POWERASSEMBLIESCUSTOMUNITS…
By Lori Culpepper
F or small- to medium-sized manufacturers that are looking to add to their production capabilities, additive manufacturing (Am) is an option to consider that will literally allow the adding of materials to create parts and products rather than taking them away.
Originally developed by mIt, Am adds materials layer by layer to create a 3D object or part. A variety of materials can be used, including plastics, metals, ceramics, or concrete, and the process brings digital flexibility and efficiency to many types of manufacturing operations. Am has been around for about 40 years, and it’s often been called an “emerging” industry. Analysis of the Am sector showed it had grown to be a $14.5 billion industry with a 22 percent annual growth rate as of 2020, according to mcKinsey & Company, a global management consulting firm that serves leading businesses, governments, non-governmental organizations, and not-for-profits.So,doesthis mean additive manufacturing has emerged, or is it still emerging?
“Certain industries have been able to leverage the mass customization capabilities and increased value through freedom of design using Am , such as the medical and dental, and aerospace industries,” Weston says. “but I still think the Am industry is ripe for innovation that will continue to drive adoption.”
“I believe these are still ‘low hanging fruit’ opportunities, and for that reason, I’d still consider Am an emerging industry,” Weston says.
According to Jordan Weston, Director of education & Conference for the Additive manufacturing Users Group (AmUG), it depends on who you ask and what industries you are talking about.
What Is Additive Manufacturing?
One challenge or barrier that many small-to-medium size manufacturers often cite is cost. Weston says these manufacturers should understand that 3D printing is another tool in a toolbox, but it does not replace all of the other tools.
“ this opens up opportunities for producing parts that
Additive Manufacturing: ASolution that Continues to Emerge for Small- to-MediumSize Manufacturers
Optomec LENS Metal Printer with Robotic Loading ManUfaCTURinG sHowCase
When it comes to small-to-medium size manufacturers, he says AmUG is seeing Am adoption on the factory floor with assembly jigs and fixtures, go/no-go gauges, and the robotic end of arm tooling. With the constraints manufacturers are facing with the labor force, time on a 3D printer is typically more accessible than time in the machine shop. He says this translates into Am jigs, fixtures, and manufacturing tools that are a faster, less expensive alternative to machining. printing these assembly tools offers manufacturers more flexibility in their production and can help lower the barriers to implementing automation.
“Just because you can 3D print something doesn’t mean that you should. In traditional manufacturing, as complexity increases, so does cost, whereas with 3D printing, complexity is typically negligible,” Weston says.
What Does AM Mean for Small- to Medium-Sized Manufacturers?
In recent years, he says AmUG has seen a lot of development focused on better hardware, software, and materials. more and more, they are starting to see Am considered as a component of the end-to-end manufacturing solution, rather than a standalone tool. Integration between Am machines, raw material handling, post processing, automation, and the production-control systems already in place at factories are necessary to truly bring Am to production at larger scale.
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additive manufacturing is a tool that offers several benefits when successfully adopted by small-to-medium size manufacturers, but it’s often a long journey.
Weston believes Am use-cases will continue to grow, including among small- to medium-sized manufacturers. He says the fact that there has been a focus on better hardware, software, and materials, and the integration of the Am process as an end-to-end manufacturing solution is part of the maturation stage of the Am industry. this will help bring it in line with some of the expectations that the traditional manufacturing industry has already set. “Additionally, all signs are pointing at the labor shortage being here to stay. As manual laborers continue to get upskilled into higher value positions, lower cost robots and cobots have lowered the barriers for smaller firms to get into automation,” Weston says. these solutions can perform complex tasks and increase manufacturing flexibility, and with each task likely having a need for customized end of arm tooling, the opportunities for Am are immense.
Another current challenge related to manufacturing is supply chain issues. Additive manufacturing is being called in to help in this area as well. Sintavia, LLC, a designer and additive manufacturer of advanced propulsion and thermodynamic systems for the aerospace, defense, and space industry, recently announced that it has been chosen to represent the Am supply chain in the launch of a new government initiative called “Am Forward.” t he compact will focus on building a more resilient and innovative supply chain through investments in small and medium-sized companies that adopt new technologies such as A m . It also aims at helping overcome coordination challenges that limit the adoption of new manufacturing technologies such as A m , and will help develop regional A m ecosystems to enhance domestic production of high-value industrial products.
Benefits and Challenges with AM
INDUS tr IA L MACHINERY DIG e S t COm IMD | 23 would see pain points with traditional manufacturing –consolidated assemblies, light-weighted designs, or low volume production of complex parts that tooling costs were prohibitive with in traditional manufacturing.” but he adds that very rarely will additive manufacturing be a simple drop-in replacement for other manufacturing processes, and companies that take a bigger-picture approach to understanding the current design, how it interacts in its assembly, and how additional value can be added to the system are the ones that have the most success implementing 3D printing.
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As the field matures and initiatives such as A m Forward begin to make a difference, more manufacturers transitioning to A m will be critical for expanding its use by industry and allowing small-tomedium size businesses to understand the benefits and adopt A m technologies.
According to mcKinsey, Am technologies offer four potential sources of value when compared with traditional production approaches.
David ramahi, CeO/president of Optomec, a privately-held, rapidly growing supplier of additive manufacturing systems, says there is no doubt that most companies will experience a prolonged journey to introduce a new manufacturing technology into industry for production. “the truth of the matter is that there is a very high hurdle to having an established successful manufacturing company transition over to a previously unproven solution, since the performance of their own products is their lifeblood,” ramahi says. “this situation is exacerbated in the highly regulated markets that Am tends to target; (i.e., aerospace, defense, and medical devices); however, at the same time it is precisely such high-value, lower volume end markets that are most amenable to adopting new technology because in many cases function will outweigh cost, and their end-products have the pricing and margin power needed to absorb any additional cost.” In parallel with these underlying market dynamics, he adds that there are realities to Am solution development that pose technical, financial, and lead-time challenges. He sees the market development of Am solutions happening in phases, such as: » Core technology – the printing process » product – the printing equipment » ecosystem – ancillary elements, such as materials and post-processing » Use Cases – the printing application » return on Investment (rOI) – the printing value proposition » Accounts – the early adopters » markets – the broader opportunity “each of these steps can literally take years to unfold,” ramahi says. “All that said, Optomec is fortunate to have successfully traveled this path with dozens of blue-chip customers, including Ge, Siemens, raytheon, Honeywell, and Caterpillar, as well as the US Air Force, Navy, and sales@carellcorp.com sales@eaglebendingmachines.comwww.carellcorp.com•www.eaglebendingmachines.comSectionBenders
» the ability to generate almost any 3D shape allows designers the freedom to create parts that perform better or cost less than conventional alternatives.
» Since there is no need for molds or fixed tooling, every part produced by a machine can be unique, paving the way for mass-scale customization.
Despite these benefits, manufacturers have cited several barriers to their use of Am , such as the slow speed and limited build volume of Am hardware, the need for vendorspecific software, high-cost materials needed specifically for Am , and cost of additional processing required.
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» Simplifying the maintenance and support of products in the field reduces the need for spare-parts inventories by enabling on-demand production of items from digital files.
» eliminating time-consuming toolmaking and fabrication operations accelerates both product development and production, reducing time to market.
Lastly, ramahi says that there are no shortcuts.
Keeping the success of Optomec in mind, the journey the company has been on, and lessons he’s learned, ramahi has several pieces of advice for small-to-medium size manufacturers that might be hesitant to adopt Am or those unsure about embracing it. “Look for value-add Am opportunities in your current product designs, rather than feeling obligated to leverage Am’s novel geometric and material capabilities in wholly new and radical design paradigms,” he says. He also recommends considering additive repair as an entry point, because it is a high rOI, high throughput application, and it has the added benefit of instilling confidence in the technology. “Adding a little bit of material can add a lot of value,” ramahi says.
“Seek to replicate others’ successes. there are relatable, real-world production examples from early adopters. Learn from their failures, as well,” he adds. “Don’t wait for comprehensive standards to emerge. they can be mired in bureaucracy for years, letting cost-saving opportunities pass you by.”
INDUS tr IA L MACHINERY DIG e S t COm IMD | 25 Army, representing a range of applications and markets. We now have more than 600 industrial printers installed, with hundreds of these machines used in daily production resulting in millions of end-products shipped across both 3D metal and 3D electronics applications.”
Introducing new manufacturing technology will require time and investment, so companies should evaluate the economics at the outset to ensure there is a compelling rOI to make the internal business case. Conclusion So, what will the future of Am look like as it continues to emerge? “I think it would benefit from a little less hype, and a lot more execution, especially in terms of delivering demonstrable rOI to production end-users,” ramahi says. “If we can under-promise and over-deliver, the future will be as bright as our lasers.”
ABOUT THE AUTHOR Lori Culpepper is a contributing writer for Industrial machinery Digest based in the birmingham, Alabama, area. She has more than 16 years of experience writing about a variety of topics for many different industries — especially in the b2b market. Sources 1. our-insights/the-mainstreaming-of-additive-manufacturinghttps://www.mckinsey.com/business-functions/operations/ 2. mAhome/20220508005087/en/Sintavia-Chosen-to-https://www.businesswire.com/news/represent-m-Supply-Chain-for-Aerospace-Defense-in-Launch-of-ajor-White-House-Initiative 3. our-insights/the-mainstreaming-of-additive-manufacturinghttps://www.mckinsey.com/business-functions/operations/
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26 | IMD September 2022
Q&A with Edgewater Automation
How have you seen modern automation-focused manufacturing practices like 3D printing reshape traditional manufacturing for small-, medium, and large-scale manufacturers? We use 3D printing every day in a myriad of ways. We use it to prove our tooling, make sample parts to help us develop processes, and, in some cases, to 3D-print parts for our machines when other methods are either impossible or too costly.
Please give me an overview of the automationminded products and services Edgewater offers. edgewater focuses on custom assembly and test equipment, robotic integration, material handling systems, process equipment for multiple industries as well as ovens and dispensing automation. by having our own design, manufacturing, assembly, software development, and installation services all in our capability we can move quickly and effectively for our customers. We invest not only in equipment but the people and skills it takes to make one of a kind automation work right, right away. Our customers need solutions that cannot be found in the marketplace. these solutions need to be invented or customized to a point to meet their specific needs.
Please walk me through Edgewater Automation's "core competencies." How do these set it apart from other service providers and machine shops in the industry? the core competencies start with our applications team, which helps create the specifications and proposals to meet the custom demands of our customers.
inDUs TRial fabRiCaTion & aUToMaTion
Join our conversation with Rick blake from edgewater automation. Could you please give me some background information on Edgewater Automation, including its history and inception, as well as what led it to offer the new fabrication, manufacturing, and machine shop? In 2001, edgewater Automation started with a handful of employees in a 5,000 square foot rented facility in St Joseph mI. the company finished 2001 by moving into brand new plant. Over the years, this plant has grown to over 48,000 ft in our St. Joseph, mI, location. In 2013, edgewater opened its new 40,000 sq ft Spartanburg, SC, facility. the Spartanburg plant and the St Joseph plant are sister plants with complete design, build, integration, test, and installation capabilities. We started our plant in Spartanburg to better serve our customers in the southeastern part of the US. In 2014, we opened a 35,000 sq ft manufacturing plant in buchanan, mI. We opened this plant to allow us more flexibility in building our customer automated machines and to create faster turnaround times for the fabrications and machined parts needed. We also found others wanted this capability and we have be able to expand what edgewater offers to more companies in various industries. We use lasers, CNC benders, and CNC machining cells to better meet our growing needs. We have a new Haas Gantry mill. In 2020, we launched both our buchanan Automation group and our large system build space in buchanan, adding an additional 160,000 sq feet. Across all the plants we have design engineering, manufacturing, and assembly staff led by experienced project managers and technical leads. Currently, we have 235 people across all sites. Tell me more about the machine shop itself and the staff/operators who work there. We have CNC machine shops in all of our plants to allow us to make the parts we need when we need them. We want complete vertical capability whenever possible, even if we don’t have all the capacity we might need. Our plan is to be able to make our parts to keep our customers’ project moving at all times. We have grown our fabrication business understanding that we need to include other customers outside the automation customers we have to better equip our capability.
Our machine designers take these concepts and turn them into the print packages that will allow us to build a custom machine designed for our customers specific and special needs. Our build team knows what it takes to bring a one-ofa-kind piece of equipment to life, providing long term solutions that have been producing our customer’s products for the past two decades. Our controls engineers program the robots and pLC’s to make sure the system is running reliably. We do a complete FAt on our floor with our customer’s parts to ensure the machine meets all their needs prior to ever shipping. Our Controls team works on making sure the interfaces to the customer’s factory floor system and their production teams are set for success.
We are looking at growth. Our growth in health care has been our fastest growing segment and we see that continuing for many years. energy is another sector we see as a good opportunity for automation. there is opportunity in the market for expanding automation into new fields and helping our current customers grow. Is there anything else you'd like to include that I haven't asked?
We had to learn to work differently and work around supply chain stoppages. We had to be more flexible and moreOnecreative.waywe worked differently was the remote work we had to learn to do. Designing custom equipment is never easy, but when you can’t meet face to face it was made harder. We learned how to work on designs in steps that could be communicated via web-based meetings, even web based FAt. When our customers could not travel to do the factory acceptance test, we took that test to them. We set up cameras and headsets and performed the FAt virtually. Not as good as the real thing, but close. We were proud to have made ppe on short notice to help local responders in southwest michigan. As for supply chain, we had to get creative, in some cases changing our designs to solve problems with the parts we could find.
How was the company and its clients affected by the COVID-19 pandemic, and what does business look like now that we're getting back to normal life?
Where do you see the world of manufacturing, metalworking, and machine shops headed in the next 10 years? (More specifically, in regards to IIoT and automation. i.e., 3D printing, lights-out manufacturing, dark factories, robotic automation, etc.)
Industry 4.0 is everywhere and as data becomes easier to connect we seem to want more and more of it. Integrating these data points to your automated process and helps uptime, increases safety, and helps continually improving the process. As robots learn they can also become more effective. Automation will continue to expand and grow, Industry 4.0 will help us do this safely and increase our ability to learn
IMD
– North America’s Manufacturing Resource for Industry Professionals Since 1986
ABOUT THE INTERVIEWEE rick blake is the founder and president of edgewater Automation. He has been in the custom automation field for 40 years. For more information, please visit edgewaterautomation.com.
A service we’re getting really good at is that we are always creating new ways of applying innovative engineering to our customers’ projects so that they can do things they never thought they’d be able to, or that help them solve problems they have. Internally, we share the problems and solutions our teams came up with with the rest of the team so that everyone can learn a better way of doing things from one another. A new product we’re proud of is the mobile robot we recently designed and built for one of our customers that saves their workers a lot of heavy physical labor.
INDUS tr IA L MACHINERY DIG e S t COm IMD | 27
We are focused on the automation side of the business, and we are seeing more and more people driven to automation. As the supply chain is challenged, automation is becoming more flexible and people are so hard to find. We foresee that in the next 10 years our customers will want to build their products closer to their customers. In the U.S., this will mean more automation, and more robots. Are there any new products or services you'd like to highlight?
Industry 4.0 is quickly becoming more and more commonplace in manufacturing environments around the world, particularly here in the U.S. However, smaller machine shops sometimes struggle to keep up. What advice would you offer a smaller manufacturing operation that is considering adopting automation but may be uneasy to move away from the way things have always been done? Doing nothing is the wrong answer; start by doing something. tie one piece of your process to a report or downstream process that you know you can be successful with. then grow from there. We are supplying more and more robots that can tie into other processes for smaller companies than ever before as people are so hard to find.
We also started a new health and wellness innovation company, edgewater Safety, and were recently awarded a $500,000 grant from the National Institute of Health to develop a wearable medical device for dementia patients. It has the potential to be a game changer. this is a new area for us, and we’re excited about the potential to mitigate agitation in those with Alzheimer’s and related Dementias. my mother died of Alzheimer’s, so it hits close to home for me. We’ve partnered with rush University medical Center in Chicago for a clinical trial of our device that’s funded by the grant.
What's on the horizon for Edgewater Automation?
Cobots have previously demonstrated the potential of multiplying capacity within the machining and fabrication industries. they allow toolmakers and machinists to focus on high level skills and tasks while these types of robots can also handle the mundane, loading and unloading of parts. In many cases they transfer the finished objects to an automated inspection system. It is this sort of capability coupled with the affordability of new precision automated inspection and assembly technology that will drive capacity expansion while meeting the demands of ever-expanding QA/QC requirements for critical products such as medical devices, microelectronics, automotive and aerospace components. the adoption of cobots is likely to be core to the industry focus when it comes to labor force training and development. Critical training programs for millennial and Gen Z employees are likely to be established over time that take in automated and semi-automated loading, assembly, and inspection QA/QC tools. In her book, “ the New-Collar Workforce: An Insider's Guide to making Impactful Changes to manufacturing and training,” Sarah boisvert, emphasizes that both generations have the inherent digital skills needed to run automation, software, design in CAD, program sensors together with experience of data collection and analysis. targeted automation and specifically flexible automation should be considered a means to help bridge the workforce skills gap, permitting existing highly skilled employees to focus on the critical process operations and freeing them to simultaneously help train the new generation of employees within the company. to be competitive in the global marketplace, meet their growth targets and reduce manufacturing costs, it is clear industry needs to adopt a hybrid automation approach while local education ought to consider a redefinition of “blue collar” work as more akin to “new collar.”
By Todd Lizotte, Bold Laser Automation, Inc.
A s the established high-tech sector continues to experience an increasingly aging workforce, it begs the question, where are the millennials and Gen Zs to fill these jobs especially in light of the fact that the majority of this aging workforce is actually nearing retirement? In fact, an alarming labor shortage has been emerging for a number of years, exacerbated by the global shutdown endured as a consequence of the COVID pandemic. the knock-on effects are now impacting both ends of the corporate spectrum, from the smallest startups to well established, household names. Independent of their size, is the very real threat to operation and efficiency should the skills shortage not be addressed.
28 | IMD September 2022 woRkfoRCe De VeloPMenT
An infusion of young talent is one solution but where will they come from given an educational back drop that inculcates a message that seemingly points to white collar jobs being the only way to success? What is lamentable, in my view, is that should Gen Z even be successfully encouraged to enter the sector, your corporation probably can’t afford the time to recruit and bring them up to speed, requiring, as is typical, five to ten years to train them. maybe a different strategy is necessary, one that embraces augmenting the labor force with collaborative robots (or, for short, “cobots”) those game-changing pieces of equipment that appeared in 2016 and have gained greater prominence since. there is a compelling argument that leveraging the predominant skills of both the millennial and Gen Z labor force in combination with the flexibility automation and robotics will increase your production capacity whether the cobots engage in direct human robot interaction or share within a space.
Automation-Enhanced Workforce
Dovetailing production process bottlenecks and skills gap analysis with targeted capital equipment acquisition and workforce succession planning, I’ve arrived at a concept that I’m coining an automation-enhanced workforce strategy (AeWS). It is a concept I have via my company bold Laser Automation based in bedford, New Hampshire. AeWS starts with production process analysis, determining the best opportunities for you to make small incremental automation tooling asset additions within a production line or production cell. the automation is strategically incorporated based on comparing and contrasting workforce needs or the skills gaps in conjunction with your current production process capacity. It also takes into account your ability to scale, underpinned, as this is, on your short-term and long-term goals and objectives.
Could targeted automation and specifically flexible automation be a way to bridge or even close the workforce skills gap?
INDUS tr IA L MACHINERY DIG e S t COm IMD | 29 IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986 p art of the approach involves alleviating those employees, identified as having vast experience and knowhow (aka critical staff), from the more mundane or repetitive tasks giving them the freedom to impact on their and the company’s overall productivity. For example, the addition of simple automated gauging or vision inspection platforms could see components placed onto a locating fixture for critical dimensions measurement, stored and analyzed while more sophisticated work is Withinundertaken.industrytoday, for example, skilled CNC operators on 5 Axis turning systems, producing tube based medical devices, continuously hit bottlenecks with downstream processes. these include the need for washing and drying prior to critical inspection that’s usually measured by hand causing further bottlenecks while always introducing the possibility of human error. With the installation of vision automation elements, product flow can be maintained while enhancing the productivity of the skilled employees or even obviate the need for skilled labor recruitment or retaining. perception is also an important aspect. the limited appeal of table hand product inspection, the soul-destroying nature of measuring widgets with a gauge day after day, for example, either results in a skilled laborer seeking alternative employment or prevents them accepting such work in the first place. bringing automated inspection machinery into the mix completely changes the dynamic and enhances the prospects of an identifiable growth path. Finally, why is this issue so important to startups as well as large manufacturing facilities? Well, according to the National Association of manufacturers and a new study “the manufacturing skills gap in the U.S. could result in 2.1 million unfilled jobs by 2030.” As a direct consequence of these missing jobs, they project that the cost to U.S. manufacturers could total $1 trillion in 2030 alone. It is estimated that about 1.4 million U.S. manufacturing jobs were lost during the early days of the pandemic, hindering the manufacturing labor force by more than a decade and although the manufacturing industry did recoup >60% of jobs lost, it is still acutely suffering from an urgent skills shortage. Amongst the ongoing difficulties manufacturers say they are experiencing is the ability to attract and retain workers with so many manufacturing jobs remainingSomethingunfilled.has to change. An automation-enhanced workforce might be the step-change that ushers in this new era in manufacturing.
ABOUT THE AUTHOR todd Lizotte is the president, CeO, and Director of business Development for bold Laser Automation, Inc. For more information, visit www.boldlaserautomation.com.
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alstom is working together with Replique’s on-demand additive manufacturing platform to produce customized industrial-grade serial parts in order to digitize its supply chain and produce small batches on demand and decentrally.
A lstom, a global leader in green and smart mobility, is using replique’s on-demand 3D printing/additive manufacturing platform to produce customized industrial-grade serial parts. by digitizing its supply chain, Alstom can now produce small batches on demand and decentrally. this enables the company to respond even better to its customers’ needs. replique reduces the complexity within the supply chain so that first series are not only produced faster, but also cost-competitive.
As a result, parts can be produced economically even in small quantities. Alstom has already taken advantage of the technology within the production of spare parts. Now, they can also fulfill specific customer needs using additive serialSinceproduction.Alstom operates worldwide and each train component has different requirements, they need a scalable solution for decentral manufacturing in industrial grade quality. Alstom therefore works closely with replique, leveraging the expertise and capabilities of a 3D printing network where all partners are carefully selected and qualified.
Careful material and technology selection lead to high quality and durable end parts printed with Ultrafuse® 316L. Image Courtesy: RepliqueReplique was able to qualify and produce the doorstopper for additive serial production within just 1.5 month. Image Courtesy: Alstom
In train manufacturing, small batch sizes lead to high manufacturing costs due to the production of molds and other tools. 3D printing can solve this challenge by eliminating fixed costs.
30 | IMD September 2022
Alstom Partners with Replique to Implement First Serial Production Part Using Additive Manufacturing
“Additive manufacturing is now a key part of our supply chain. With replique, we benefit from 3D printing and materials expertise, as well as a decentralized manufacturing network covering all relevant locations and technologies. their end-to-end services enable us to respond faster and more cost-effectively to different customer requirements,” says ben boese, 3D printing Hub manager of Alstom transport Deutschland GmbH.
“ the additive manufacturing market is still very fragmented, which makes it impossible for end users to find an optimal solution for each part. With replique, we benefit from all major additive manufacturing technologies
new TeCHnoloGy
including the selection of the right material is crucial. the doorstopper must not only fulfill its function over the entire service life of the train, but also meet high aesthetic standards, as it is a visible part inside the train compartment. Stainless steel meets these requirements. Of course, the doorstopper should also be manufactured cost-efficiently. thanks to FDm 3D printing with Ultrafuse® 316L from Forward Am, brand of replique’s material partner bASF 3D printing Solutions, followed by debinding and sintering, replique was able to significantly reduce costs compared to other additive manufacturing processes, such as powder bed with 316L.
“Alstom has already shown in the past how 3D printing can be integrated in a lean and cost-efficient way. they are pioneers in additive manufacturing, and we look forward to supporting them on their journey to simplify and fully digitize their supply chain for all printable series and spare parts,” says Dr. max Siebert, CeO and founder of replique.
ABOUT REPLIQUE Founded by bASF employees from the fields of materials science and digitization, replique provides a secure digital platform that enables Oems to provide parts on-demand to their customers through a global and decentralized 3D printing network. As an end-to-end solution, replique supports its customers along the entire value chain, including design, technology and material selection, and digital warehousing. For more information, visit www.replique.io.
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INDUS tr IA L MACHINERY DIG e S t COm IMD | 31 and materials from a single source. In addition, we receive optimal technological preparation,” says boese. the flexibility of replique’s platform is shown in a first use case within Alstom’s Oem business. to meet a specific customer request, Alstom needed several doorstoppers for a partition door that will divide the passenger compartment of a diesel multiple unit into a first and second class. the small number of such components is usually an obstacle to initial production and typically, it comes to project delays as a result of long delivery times. therefore, Alstom chose additive manufacturing as the production method. replique assisted Alstom with material and technology selection and was able to qualify and deliver the doorstopper for serial production within just 1.5 months. During this process, the doorstopper went through the protocols of initial sample testing and assembly and received the final approval for series production. “We were able to produce the doorstopper in a cost-neutral manner compared to conventional methods. Within the near future, we plan to further exploit the technology’s potential by creating topology-optimized designs of new parts, or even make them lighter by using reduced infill,” explains boese.
Advanced Materials Enable Cost-Efficient Additive Manufacturing of the Doorstopper to enable on-demand production, careful qualification
Calk: the biggest investment any organization makes is its employees. the higher the level of training a company provides its employees, the higher the net return they realize on this investment. We offer a broad body of training from lubricant fundamentals and reliability to asset management and rotating equipment. We deliver this training for our 8
What does it mean for Lubrication Engineers to be "a one-stop shop for lubrication reliability?" Tell me more about that and what sets this company and its products apart from its competitors.
Q&A with Lubrication Engineers
32 | IMD September 2022
Grimes: What sets us apart is our holistic approach with lubrication programs. You can purchase the best lubricant in the world, but if you do not take care of it and keep it clean, dry and contaminant-free, it will fail. A good lubrication program can extend the longevity of the lubricant, protect the equipment, and increase uptime. In addition to the right lubricants for the applications and a host of reliability products for taking care of them, Le has boots on the ground to help plants around the world stand up their lubrication programs.
Tell me about your in-house and in-the-field training Grimesopportunities.
Our portfolio allows our customers to get most of their lubrication reliability products from one supplier, rather than needing a procurement team to set up multiple vendors.
Calk: Lubrication reliability impacts all facets of the maintenance budget and is critical to operational efficiency. When lubrication reliability is not at the forefront as a maintenance strategy, it will negatively affect other cost centers, including annual lubricant expenditures, reactive labor, capital cost, spares, machinery unavailability, and downtime. When overall operational efficiency is not achieved, quality, production and profits will decline.
Grimes: the cost of the lubricant is a very small part of the overall cost of running an operation; however, it can have a dramatic impact on the performance and longevity of the equipment. It ends up being a large, often overlooked area that can provide a great wealth of benefits to any organization.
: training instills an appreciation of the importance of lubrication and its role in helping equipment run properly. It helps create an understanding of the lubricant’s function and the surrounding forces that can impact it. We offer virtual and in-person training for those who want to become knowledgeable and certified in machinery lubrication. It is a natural first step for teams to become empowered and be able to move their programs forward.
Join our conversation with Paul Grimes, Coo of lubrication engineers, and Clay Calk, the company’s director of market development. Grimes has been with lubrication engineers for the last 13 years, and Calk has been with them for 23 years.
What role does lubrication reliability play in overall system reliability for manufacturers and maintenance teams?
SUS420J2420 / S4200051X20Cr13 SUS440C440C / S44004 SUS630S17400 / S1740058 Copperalloy JISASTMENDIN CAC703CC95800CC333GCuAl10NiCAC702CC95400CC332GCuAl9NiCAC503CC91000CC483KCuSn12CAC502CC90700CC480KCuSn10 In case of requirements is normally used. Values of hardness is Actual expected hardness Notes of Gear precision Above mentioned equivalent Not all grades completely catalog_usa.indb 8 PRoCess
Calk: plants striving to achieve lubrication excellence demand products and services from their suppliers to support their asset optimization and reliability programs. Understanding the criticality of these initiatives and the impact they have on asset lifecycle, quality, efficiency, and profitability, we strive to provide the highest quality products and services to exceed our customers’ expectations.
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What's on the horizon for Lubrication Engineers moving forward? Grimes: We continue to invest in the business with great people, products, capital, and infrastructure. We believe by investing now we will be even more prepared to help our customers meet the unknown challenges and demands of the future. We have been practicing a steady stream of creative destruction internally and working on our continuous improvement culture. We want to make sure we are ready to continue helping customers across the globe with their toughest lubricant challenges. For more information, visit: www.lelubricants.com.
Let's talk about products. Which new products is Lubrication Engineers offering? Tell me all about them and what makes them the best option for manufacturers and industry members.
Grimes: After 4 p.m. on a recent Saturday afternoon, one of our lubricant consultants received a call from a long-time customer in pennsylvania in desperate need of four drums of our gear oil for a new $1 million gearbox that had just been installed and was set to start running that monday. the Oem had given them the wrong fill volume information, and they needed the oil by monday morning. the consultant contacted our customer service manager for assistance. One of our warehouse managers went to our tennessee warehouse to pull the drums, and our traffic manager found a driver to pick them up. All on a Saturday afternoon and evening. this is an example of the type of relationships we have with our customers and the extraordinary efforts we go through to make sure they get what they need.
An oilfield services company on the north slope of prudhoe bay, Alaska, owns 20 John Deere rolligons, each custom-made to the tune of roughly $2 million each and used for transporting drill rigs to remote sites. each rolligon has 12 baghouse tires and 24 spherical roller bearings. extreme conditions were causing more than 100 bearing failures per year. Switching to our Almaplex Ultra-Syn Lubricant reduced roller bearing failures by 73% and helped the company save approximately $196,200 per year.
Last year we launched the Xport Ultra Lubricator, a fully automatic single point lubricator that is independent of temperature and counter pressure and offers precise discharge. It is suited to applications that demand high lubrication rates and where long remote grease lines are necessary to ensure safe access.
What type of R&D projects are y'all working on at the Grimesmoment?
How was the company and its clients affected by the COVID-19 pandemic, and what does business look like now that we're getting back to normal life?
Grimes: maybe it was luck and maybe it was great planning or a little bit of both. We had the infrastructure and culture in place to quickly adopt a work-from-home culture. COVID hit and our employees left the office and our consultants got creative to keep customer projects and products flowing. We also stocked up on lots of inventory to make sure we could keep supplying customers with little to no interruption. the lubricant industry is a community of great people, very connected, with many companies working together to make sure customers’ needs were met. this has been a challenging period for all of us with price increases, supply chain delays and interruptions, but I think we are all starting to see some light at the end of the long tunnel.
Grimes: We are excited about partnering with easy bar to bring to market this year a solid lubricant bar that incorporates some of our proprietary knowledge to elevate kiln and dryer protection to a new level.
: Due to the volatility of the lubricant supply chain the past few years, our efforts have been spent looking at suppliers around the world to make sure we have redundancy built into our lubricant formulas, ensuring that we can keep producing without interruption and without sacrificing quality.
Our comprehensive enclosed gear oil line continues to be highly popular for its ability to protect and extend the life of gearboxes while extending drains. We offer several different high-performance gear oils – including Duolec, Almasol, H1 Quinplex, multilec, and monolec varieties – all formulated to meet the needs of specific types of applications.Duetotheir performance characteristics, greases featuring calcium sulfonate complexes as thickener are gaining a lot of interest from our customers. Among these characteristics are inherent prevention of rust and corrosion, exceptional water resistance, inherent extreme pressure properties, very high dropping point, excellent mechanical stability, and very low oil bleed. Like our other products, our three calcium sulfonate complex greases – monocal, Almamoly, and H1 Quincal – are formulated to meet the needs of specific applications. Can you give me an example of how the company stepped in to help clients in crisis with their lubrication and reliability needs and what the solution was?
34 | IMD September 2022 employees and customers through a variety of means, such as online and in-person classes, virtual presentations, printed collateral, web, and on-the-job training. We have learned over the past 70-plus years that the best customers are the ones who are open to learning and willing to pursue continuous training.
A large regional brewing company with four air compressors was seeking to reduce costs by extending drain intervals and asset life. After switching to our multilec Industrial Oil and using oil analysis to monitor oil condition, they were able to extend drain intervals up to eight times the Oem recommendation. In less than a year, they saved $71,000 in replacement oil cost and eliminated 273 gallons of waste oil. Fewer oil changes also meant less downtime, maintenance and labor.
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Normal time is the time taken by a worker to complete the task at a normal pace. Allowances are used to account for scheduled and unscheduled breaks. the analysis of the output of time and motion studies has to be done on two different scales, the micro, and the macro scales. Analyzing each therblig to identify ways to improve the motion and reduce the time taken to perform tasks is micro analysis. Analyzing the overall range of motion and the time taken to perform the process is macro analysis. macroanalysis has to be performed first. If the overall motion scheme of the process has to be altered for improvement, there is no point in analyzing each therblig.
the purpose of conducting time and motion studies is to optimize industrial processes. You need to analyze the findings from these studies. the analysis has to be performed on each individual task. this analysis should lead to identifying ways to improve the time taken to perform the task. Similar analysis has to be done for therbligs of the process.
The Next Steps
A key metric to be calculated is standard time. It is the time taken for a normal worker to perform the task in standard conditions.
» Identify ways to improve production efficiency
» Unearth hidden flaws and weaknesses in your industrial process
» pinpoint inefficient allocation of resources » efficiently plan production schedules
» Analyze how efficiently work is performed in your facility
inDUs TRy insiGHT
find out why time studies remain a critical method of data collecting in plant settings, as well as the do’s and don’ts of conducting and analyzing time and motion studies. P rocess optimization is critical for improving productivity, increasing output, and eliminating waste in your plant. Cost reduction is another benefit of industrial process optimization. process optimizations should be conducted on the basis of hard data. time and motion studies are a great tool to aggregate comprehensive and exhaustive data on industrial processes.
MotionTimePerformingOfAndStudies
» Improve inventory management » reduce overall production cost
» Create a target and time-based incentives
Time and Motion Study t ime and motion studies are among the fundamental tools managers can use to measure the efficiency of plant operations. Frederick Winslow taylor, the pioneer of scientific management, introduced time study in manufacturing. Frank and Lillian Gilbreth introduced a motion study. t ime and motion studies are performed on predictable and repetitive actions that take place in your plant. t ime study measures the time taken to complete each process in the plant. m otion study analyzes the distinct motion a worker performs to complete the task. Any complex task can be broken down into a smaller, simpler set of movements called t herbligs. t he time for the complete process and for each t herblig can be measured and recorded. Video cameras can also be used for observation in both cases – for workers and robots. t ime and motion studies are used to set the expected operating times in the manufacturing industry. t hey are used to standardize the motion and time taken to perform a task. In addition, they are performed on a large number of workers performing the same process. In modern factories, the performance of automated robots can also be analyzed with time and motionKeepstudies.inmind the variances that could occur when different employees perform the same task. Fatigue experienced by employees plays a role in how they conduct the process. Any other external factors like delays in raw materials can also have an impact on the time taken to complete the process. It’s important to consider personal, fatigue, and delay factors ( pFD) in observations to adjust the observed times.
36 | IMD September 2022 The Do's And Don'ts
Standard time = Normal time x (1 - Allowances)
the reasons for, and benefits of performing time and motion studies are:
Need and benefits
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» Identify if the worker you are observing is deliberately performing the tasks slowly. You can ascertain this by enquiring the work efficiency of the worker with supervisor, coworkers, etc. If you identify that is the case, adjust the recorded observations accordingly.
» If a worker performs tasks faster than the rest of the workers, you need to ensure the pace of the work is normal for that particular worker. You need to adjust this in the recorded time. » perform macro analysis of time and motion studies before microanalysis to save time. because, if the overall motion scheme of the process has to be altered for improvement, there is no point in analyzing each therblig with microanalysis.
» typical personal, fatigue and delay factors (pFD) lie in the range of 5-10%. You need to incorporate this factor into your recorded observations.
Tick … Tock … time and motion studies are widely used in manufacturing facilities to evaluate the productivity and efficiency of industrial processes. these studies are commonly carried out by experienced industrial engineers. they observe and measure each movement of the worker or robots performing the task. this data can be used to analyze the processes for avenues for improving the motions performed to complete the task. Avenues to reduce the time to perform the task is another outcome of the analysis. Adhere to all possible best practices for optimal results.
» make sure no time and motion studies have been done prior to you. If there are, refer to the old studies before performing your study.
» try to use decimal minute watches to measure and record time. most decimal minute watches go up to the third decimal of minutes measurement. this makes calculations easier.
» the person conducting time and motion studies should have relevant knowledge and experience in conducting these studies. Industrial engineers with experience of performing time and motion studies are generally tasked with undertaking it. Consulting companies that specialize in time studies can also be chosen to perform the study at the plant.
» Identify a clear physical set point that triggers each therblig. the process you are observing is made up of many therbligs. Grabbing objects, touching some points, etc, during the process are perfect trigger points.
ABOUT THE AUTHOR bryan Christiansen is the founder and CeO of Limble CmmS. Limble is a modern, easy-to-use mobile CmmS software that takes the stress and chaos out of maintenance by helping managers organize, automate, and streamline their maintenance operations.
» take advantage of the law of large numbers. Observe and record multiple repetitions of the process. Your findings will eventually approximate close to the true average of observations.
» Set clearly defined goals and objectives before performing time and motion studies. the defined goals and objectives determine the processes that need to be studied. It could be increasing the speed of processes or eliminating unnecessary actions. You need to have the goal defined in qualitative and quantitative terms before the studies are conducted.
» the last step of the process should lead to the trigger point of the first step since you are observing repetitive processes. If this doesn’t happen, you have not observed and timed the process correctly. In this case, it’s highly recommended to do it all over again.
» Speak to the worker whom you will be observing before the study commences. make them feel comfortable and build rapport. Speak open to them about the reason for the study and how the study will be performed. You need to explain that the outcome of the study will in no way affect the worker.
» Don’t obstruct the worker performing the task. You are there to observe how the process is carried out in normal circumstances. Your presence should not be a hindrance to the worker performing his duty. Avoid annoying those being timed.
38 | IMD September 2022 Best Practices the following are some best practices you need to consider while performing and analyzing time and motion studies in your plant.
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40 | IMD September 2022 on e xHibiTindustrial Machinery Digest's on exhibit features the latest news and press releases from companies exhibiting at the leading trade shows across north america.
Gorbel will showcase their industry leading overhead cranes and lifting systems at the International technology m anufacturing Show at b ooth # 237280 from September 12-17, 2022 at m cCormick p lace in Chicago, IL. Attendees will learn how Gorbel’s cranes and lifting devices transform material handling by enhancing productivity, profitability, and safety.… BLM Group
FOBA Presents a Full Scope of Laser Marking at IMTS FObA is attending the International manufacturing technology Show ImtS in Chicago (September 12 – 17, 2022) with three laser marking systems on-site and two sample marking giveaways. Automated mark alignment with FObA mosaic, marking on a tube using a rotary unit as well as high-speed in-line marking will be presented, in addition to the latest product developments…
Overhead Lifting Solutions at IMTS
The largest and longest-running industry trade show in the western Hemisphere, is held every other year at McCormick Place in Chicago, illinois.
At FAbteCH 2022 in booth #b7513, bLm GrOUp USA will be demonstrating its Lt 7 lasertube with a new thread insert unit, which automatically installs thread inserts into laser cut/drilled holes using press fitting. A simple and widely relied upon joining technique, press fitting relies upon force and friction to hold two components together. A patent-pending…
Gorbel To Showcase
IMTS — SEPTEMBER 12-17, 2022
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FABTECH — NOVEMBER 8-10, 2022 north america’s largest metal forming, fabricating, welding, and finishing event held in atlanta, Georgia, world Congress Center.
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Meister Abrasives USA To Participate at IMTS 2022 Superabrasives leader meister premierinannouncesAbrasivesitsparticipationthe33rdeditionoftheInternationalmanufacturing technology Show (ImtS) in September 2022. Swiss company meister Abrasives will take part in the premier manufacturing technology show in North America – ImtS. the 33rd edition of the conference will take place in September…
IMTS – The International Manufacturing Technology Show
INDUS tr IA L MACHINERY DIG e S t COm IMD | 41 IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986 Newly AbrasivesNortonEnhancedBlueFireatFABTECH Saint-Gobain Abrasives, one of the world’s largest abrasives manufacturers, will be featuring newly upgraded Norton blueFire Abrasives including belts, Cloth Quick-Change and Flap Discs, and mini Flap Discs at FAbteCH booth #C13057, located at the Georgia World Congress Convention Center in Atlanta, GA from November 8-10, 2022. Featuring a new, proprietary self-sharpening zirconia alumina… Fresh Outlook for MacBee Engineering Under New FENN Ownership FeNN, LLC is pleased to announce that it has Manufacturers and Suppliers to Come Together for 6th Annual PMA West Michigan Suppliers Night top metalforming industry suppliers will showcase their capabilities and present the latest technologies to manufacturers at a West michigan Suppliers Night on September 27, 2022, from 1:00 to 6:00 p.m. the event, hosted by the precision metalforming Association (pmA) West michigan District, will be held at the pinnacle … Formnext + PM South China: Top Event for andPowderManufacturing,AdditiveMettalurgy,Advanced 877-COMBI-56 SAFETY | S TO RAGE | EFFICIEN CY COMBILIFT.COM CMYCYMYCMYMCK Modex 8in x 4.75in Ad Amanda.pdf 1 13/02/2020 17:33 Save up to 100% more sto rage Before you invest in upgrading the infrastructure of your warehouse find out how Combilift could dramatically increase storage, improve productivity and enhance safety. Our warehouse design consultancy service is FREE and without obligation. When combined with our material handling products we can deliver possible space savings of up to 100%. So contact us today to arrange a site survey!
Messer atElementSystemsCuttingToShowcase400LUnitizedFABTECH this year’s FAbteCH show messer Cutting Systems focus will be the new and innovative compact footprint element 400L Unitized
versatile element 400 gantry cutting machines. this US-manufactured cutting machine has acceleration and speeds
support multiple laser or plasma heads
performance. these cutting machines
AwardsInauguralAGGCONEXPO-CON/&IFPEAnnounceNextLevelProgram
ChallengesTacklesSourcingSmarterSymposiumSupplyChain the inaugural ImtS Smarter Sourcing tpresentedSymposium,byImtSandheOnshoringproject, will be held at ImtS 2022 and will provide guidance, tools, and tactics to create more profitable domestic sourcing using lean and agile suppliers. the symposium runs from 8:30 to 11:00 a.m. on Friday, Sept. 16, and is part of the conference agenda at ImtS – the International…
42 | IMD September 2022 on e xHibiT - iMTs & fabTeCH
IMTS
CONe XpO-CON/AGG and the International Fluid power exposition (IFpe) recently unveiled the Next Level Awards program to exhibitors for the march 2023 show. the CONe XpO-CON/ AGG Next Level Awards celebrate exhibiting companies that are pushing the boundaries and developing next-level products, technologies and services designed to advance the construction…
Our selection of Permanent and Electro magnet lifts cover a wide range of steel lifting applications. We also specialize in custom lift solutions designed specifically for your application. LIFTING AND MORE 231.582.3100 • 888.582.0822 • WWW.MAGNETICS.COM INDUSTRIAL MAGNETICS, INC. MORE THAN A MAGNET COMPANY
Hobart to Showcase Filler Metals With Live Demos at FABTECH 2022 Hobart has announced that it will attend FAbteCH 2022 in Atlanta, November 8 to 10, sharing booths C12511 and C12711 with miller electric mfg. LLC, bernard and tregaskiss to demonstrate total welding solutions from the brands. Hobart welding engineers and filler metal specialists will be available to discuss the applications and benefits of the company’s solid… — the that can with no loss of have the…
Solutions to Keep Shops Running at Machine PavilionEnvironmentalCleaning/Components/ the solutions exhibiting in the machine Components/ Cleaning/environmental pavilion at ImtS are essential for shops to optimize uptime, efficiency, and compliance. Visitors to ImtS 2022, which runs Sept. 12-17 at Chicago’s mcCormick place, can expect to discover game-changing solutions… Bernard Semi-AutomaticToTregaskissandShowcase and Robotic MIG Welding Solutions at FABTECH 2022 bernard and tregaskiss will attend FAbteCH in Atlanta, November 8–10, sharing booths C12511 and C12711 with miller electric mfg. LLC and Hobart brothers LLC. the companies will showcase integrated
New July 2022 PMA Business Conditions Report pmA’s July report shows that 48% of metalforming companies anticipate no change in general economic activity in the next three months (compared to 50% in June), 15% forecast an increase in activity (the same percentage reported in June) and 37% predict a decrease in activity (compared to 35% last month). the report also showed little change in expectations for incoming orders, with 20%… Mate 2022SolutionsTechnologiesPrecisionatFABTECH the latest mate precision tooling solutions are at FAbteCH Atlanta in booth b7747 November 8-10, 2022. mate sales engineers will demonstrate features and benefits of the full line of solutions from tooling for punching, bending and laser consumables. mate American precision
IMTS 2022 Features
INDUS tr IA L MACHINERY DIG e S t COm IMD | 43 IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
New PRO Suite as the Next Generation Of Software Automation
the Concentric maxi torque, designed and patented by Custom machine and tool Co., Inc., is a unique bushing connection system. A single screw locks the low taper angle split bushing in place and eliminates all of the existing attachment issues. Improved hub-to-shaft concentricity. radial run out less than .001/.026 mm as assembled enables customers to attain higher drive speeds, reduce unwanted vibration, and maintain concentricity…
FEATURED?
CornerChemicalRust-ProofResistantCanopyHoods
7 Important Reasons to Choose The Concentric Maxi Torque
IntroducesIncorporatedCincinnatiThe
Corner Canopy Hood is the solution to maximizing your wasted space in corner areas. Designed to capture and exhaust corrosive vapors, heat steam, and odors when mounted over areas that have water baths, hot plates or other lab equipment. the canopy hood is molded one piece seamless of advanced composite resins that have superior chemical and corrosion resistance, are flame retardant and lightweight…
Check out KbC tools & machinery’s new online only flyer highlighting top sellers, special buys, end of lines, and new product introductions from their 12 industrial categories: cutting tools, indexable tooling, fluids, work holding, abrasives, measuring & inspection equipment, toolroom accessories, hand tools, shop supplies, power & air tools, machinery, and clearance/end of lines. New items include: Viking Drill & tool’s…
Send your latest product information to editorial@indmacdig.com
New Savings from KBC Tools & Machinery
Extremely Fast, SpaceEfficient Yaskawa GP8L Extended Reach Robot ProductionThroughputOptimizesinTightSpaces
Cincinnati Incorporated, an Ohio-based company, has just announced their new prO Suite of software: bendSim prO and Nesting prO. this new generation of software comes with an advanced set of features and functionality that surpasses CI's past offerings. Customers currently programming offline can now …
Industrial machinery Digest's monthly product Showcase features the latest from some of the manufacturing industry's top suppliers. TO BE
SHOWCASEPRODUCT
44 | IMD September 2022 PRoDUCT sHowCase
the versatile, extended reach Gp8L robot offers extremely fast performance in a compact footprint, maximizing floor space utilization for greater production efficiency. Ideal for logistics processes, this six-axis robot is well-suited for high-speed bin picking, induction and packaging tasks. Applications for assembly, dispensing…
WANT
INDUS tr IA L MACHINERY DIG e S t COm IMD | 45 IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
Visitors to booth b5507 will see first-hand the new era of press… Cosen Saws Leading Edge DisplaySolutionsSawingonatIMTS 2022 Cosen Saws is a reliable industry leader when it comes to sawing solutions. No matter the application, the Cosen team will work to help you find the ideal cutting solution that is best suited for your industry. Cosen is bringing their band saws to the International manufacturing technology Show (ImtS) 2022. ImtS takes place from September 12th – 17th in Chicago, Illinois at mcCormick…
INFO@TRIMLOK.COMWWW.TRIMLOK.COM 80 0 - 663-9507 6855 HERMOSA CIRCLE BUENA PARK, CA 90620 TRIMS AND SSEALS SEALS CELE B R ATING YEARS CELE B R ATING CALL US TODAY! 50 YE ARS AND STILL GROWING! NEW FACILITY COMING FALL 2022 ELKHART, INDIANA
Beckwood to FABTECHPressLinearHigh-TonnageLaunchServoTechnologyat beckwood press Company, a leading manufacturer of custom hydraulic and servo-electric presses, automation systems, and the triform line of precision forming equipment, will unveil their new product line, beckwood LSp™, at FAbteCH® in Atlanta.
CleaningIdealMetalAquaBlue™User-FriendlyIntroducingMulti-CleanerforFast&Degreasing madison introducesChemicalAquablue™, an alkaline detergent for removal of dirt, oil, grease, sulphurized cutting oils or metalworking fluids, and more from a wide variety of surfaces, including stainless. With superior penetrating and wetting properties, it is an excellent water-based cleaner and degreaser which is ideally suited for… Greenerd to Highlight Innovative Hydraulic Press Solutions at FABTECH Greenerd press & machine Company has announced it will be highlighting the company’s extensive hydraulic press and automation capabilities at FAbteCH booth #b5441 located at the Georgia World Congress Convention Center in Atlanta, GA from November 8-10, 2022. Application experts and design engineers from Greenerd will be available to discuss specific…
Lincoln WeldingADVVIKING™LaunchesElectricNew2450SeriesHelmets
46 | IMD September 2022 ABB to exhibit a selection of its latest robotic innovations at IMTS 2022 At ImtS 2022, September 12-17 at mcCormick place in Chicago, Abb will feature a selection of these recent robotic innovations in the North Hall (booth #236520), including versatile industrial and collaborative robots, and software advancements that reduce programming and operational complexity. Abb will also display a selection of interactive robotic educational… KUKA Brings the Future of AutomationCobottoIMTS
Altair, LG
Debuting what it terms Sensitive Cobotics, KUKA robotics will show ImtS attendees the future of automation in the form of its new Lbr iisy cobot. As ready-to-use automation, the Lbr iisy quickly and easily integrates into any manufacturing application from pre-defined production processes to open, unstructured work environments with unpredictable conditions from one job to the… New Electronic Bore Gage from Sunnen Makes Easy,GagingIn-ProcessFast,andAffordable the new pGe-6000 electronic bore Gage from Sunnen products Company allows precise control of final bore size and quality of purchased or semi-finished parts, with an instant digital or numerical readout for 100 percent inspection. the electronically amplified comparative bore gage is ideal for quick, simple, economical process control in…
Lincoln electric announced the launch of the new VIKING™ 2450 ADV Series Welding Helmets. the auto-darkening helmets feature cutting edge user interface and LeD technologies and superior 4C® optics, providing all day comfort to improve productivity. One of the features most frequently requested by welders — an integrated LeD light — comes…
Exact NamedMetrologyDistributor #HandsOnMetrologyof exact metrology, a division of In-place machining Company and a comprehensive 3D metrology service provider and hardware sales company, recently announced they have become the North American distributor of HandsOnmetrology. the new digital platform HandsOnmetrology.com was set up to share the benefits of 3D metrology with a global community. As a representative… Stäubli Robotics to Show IMTSTechnologiesManufacturingGroundbreakingat2022 the biennial International manufacturing technology Show (ImtS), billed as the largest and longest-running industry trade show in the Western Hemisphere, will take place at mcCormick place in Chicago, IL on September 12-17. In North Hall, booth 236262, Stäubli robotics will exhibit advanced robots used to help manufacturers meet new…
Altair, a global leader in computational science and artificial intelligence (AI), recently signed a memorandum of understanding with LG electronics (LG) to accelerate the digital transformation of product development. together, Altair and LG will promote research and development cooperate… Scotchman Industries To Attend Fabtech 2022 and Showcase Latest In Cold Saws, Ironworkers, And Hydraulic Presses A complete range of general to heavy-duty metal fabrication machinery from Scotchman Industries will be presented at booths #bC15301 and #bC15401. Live equipment demonstrations will showcase the features, benefits, cut quality and how the right equipment makes your job easier and gets the best results with these…
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Suhner Industrial products — www.suhner-machining.com 19
IF YOU’RE NOT LISTED, YOU’RE MISSING
the Caldwell Group, Inc — www.caldwellinc.com 7 tormach — www.tormach.com 23 trim-Lok — www.trimlok.com 45
L&L Special Furnace Co., Inc. — www.llfurnace.com 49 macmillin Hydraulic engineering Corporation — www.macmhydraulic.com 21 miSUmi — www.misumiusa.com 15 mSC mediterranean Shipping Company S.A. — www.msc.com/usa IbC pro-Line — www.1proline.com 49 radwell International, Inc. — www.radwell.com IFC royal products — www.mistcollectors.com 49
burr King mfg Co. — www.burrking.com bC Carell Corporation — www.carellcorp.com 24 Clamprite — www.clamprite.com 43 COLe tUVe Inc. — www.coletuve.com 49 Combilift, USA — www.combilift.com 41 Denver breaker & Supply — www.denverbreaker.com 47
Kanetec USA Corp — www.kanetec.com 48 KHK Gears — www.khkgears.us 33 Lenzkes Clamping tools, Inc. — www.lenzkesusa.com 3
Schweiss Doors — www.schweissdoors.com 49 Scotchman Industries, Inc. — www.scotchman.com 9 Siemens Industry, Inc. — www.usa.siemens.com/cnc 5 SIKICH — www.sikich.com/iem-guide 11 Standard Direct — www.Standard-Direct.com 48 Stor-Loc — www.storloc.com 37
Formdrill USA Inc. — www.formdrill-usa.com 29 Fortville Feeders, Inc. — www.fortvillefeeders.com 47 H&K equipment, Inc. — www.hkequipment.com 48
Accudyne products USA — www.accudyneproducts.com 38 Actek manufacturing and engineering Inc. — www.actekmfg.com 39 AttCO, Inc. DbA Syclone AttCO Service — www.skyhookmfr.com 17 Attica Hydraulic exchange — www.hydraulex.com 31 behringer Saws, Inc. — www.behringersaws.com 25 betenbender manufacturing, Inc — www.betenbender.com 35
Design-2-part Shows — www.d2p.com 47 Dynabrade, Inc. — www.dynabrade.com FC eagle bending machines — www.eaglebendingmachines.com 24 eNm Co — www.enmco.com 49 essex Structural Steel Co. — www.essexstructuralsteel.com 48
50 | IMD September 2022 aDVeRTiseR inDex MANUFACTURERSAMERICANSERVINGFOROVER 36 YEARS ARE LISTED?YOU We have launched our online, searchable directory with over 400 categories specifically designed for the industrial machinery industry.
HmI div of betenbender manufacturing — www.betenbender.com 13 ImDauctions.com — www.imdauctions.com 49 Industrial magnetics, Inc. — www.magnetics.com 42
