Industrial Machinery Digest - December 2019

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December 2019

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Table of Contents

COLUMNS

10 12

TALKING SHOP Dave Veisz Vice President of Engineering, Makerbot

BUSINESS 4.0 Why Subtlety Is Critical to Organizational Change By: Andrea Belk Olson, MSC and CEO of Pragmadik

20 14

FEATURES

20 24

MANUFACTURING SHOWCASE

Innovakote

28

WORKFORCE DEVELOPMENT

By: Tracy Skousen

Build a Multigenerational Workforce to Address Today’s Skills Gap

DEPARTMENTS

NEW TECH Can Augmented Reality Improve Manufacturing?

32 PROCESS

34

Utilizing Live Tool Speed Increasers Minnesota CNC shop uses Heimatec speed increaser to up RPM and feed rate; significantly reduces cycle time on aluminum engraving application

SAFETY & MAINTENANCE Improving Manufacturing Workplace Safety

By: Jeannine Kunz, Vice President of Tooling U-SME

14

By: Russ Willcutt

INDUSTRY INSIGHTS Improving Performance with Hand Tools Chicago Pneumatic CP3550 series expands to meet all industrial grinding and sanding needs

6 8 36

EDITORIAL DIRECTIONS INDUSTRY NEWS ON EXHIBIT PERFORMANCE RACING INDUSTRY

40 PRODUCT SHOWCASE 45 SURPLUS BUYING AND SELLING 49 CLASSIFIEDS 50 ADVERTISER INDEX

ON THE COVER

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4 IMD DECEMBER 2019

Dynabrade has earned a reputation for excellence and a position of leadership in the innovative design and manufacturing of unique portable pneumatic abrasive power tools, related accessories, and dust collection. With their total systems solutions offerings, Dynabrade is able to meet the specific needs of many industries. For more information, visit www.dynabrade.com

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I find something incredibly satisfying about the concept of a “closed loop,” especially since it can be applied to nearly every aspect of life. If you’re a gardener, for instance, you can harvest your crops, compost the inedible remnants, and then fold the resulting rich soil back into future plantings. The general idea is to take something often considered a byproduct, or even waste, and connect it back into the production cycle in a way that benefits the process in its entirety. This can involve plant cuttings or coffee grounds, in the case of composting, or when it comes to manufacturing, excess material or even data that we’ve only recently learned how to gather and utilize.

It’s a concept I applaud whenever I encounter it in manufacturing, which is more often than you might think — and increasingly so. I’ve toured facilities with brilliantly planned systems for recovering chips, separating them from the cutting fluids in which they are coated and filtering them for immediate onsite re-use.

This leads to both savings in terms of purchasing more fluids, lower fees for chip disposal due to decreased weight, and ironclad proof in the form of records proving you’ve done your duty should any disposal-related lawsuits ever arise down the road.

What we in manufacturing like best, of course, is the closed loop system that involves process efficiency. That is, cutting a test part that is scanned in-process in terms of geometry, surface defects, material flaws, etc., with the data being immediately returned to the first stage so that corrections are made and the second piece is exactly what the initial design intended the part to be. This saves an incredible amount of time, tool and machine wear, material, and frustration.

Every shop I’ve visited that has adopted this approach has become a huge advocate, with remarkable results as immediate proof.

This isn’t just some pro-green, tree-hugging movement I’m referring to. The key for bottom-line business owners is to identify a certifiable benefit, and all the closed-loop scenarios I’ve studied have resulted in significant operational savings. It’s part of continuous improvement, streamlining operations so that in-house recycling makes sense — both financially and otherwise — and waste is reduced, if not eliminated.

33 YEARS

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Shane Bell, Creative Director sbell@indmacdig.com

SALES

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Russ Willcutt Editorial Director, Industrial Machinery Digest

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6 IMD DECEMBER 2019

Industry News BIG KAISER Brings Back Popular Boring Kit Promotion Just in Time for the Holidays

GF Divisions Expand in Canada With New Facility, Direct Sales and Service

For the second consecutive year, BIG KAISER is offering to gift your favorite manufacturing skills training program with a free high-precision boring head kit. Now through the end of December, when you buy one boring kit, BIG KAISER will donate an identical kit to an educational institution of your choice. The SERIES 112 BORING KIT is a ready-to-go high-precision boring head kit that provides everything you need to tool up for boring jobs in a range of diameters from ø0.700-inch to 6.000-inch with just one boring head. The tooling and carefully selected accessories come stored in a custom carrying case with foam inlay to keep the components organized and to protect the instruments when not in use. The kits includes inserts suitable for fine boring of general steel and cast iron. The only necessary item not included is the shank, which must be purchased separately to match the taper of your machine. There are two easy requirements to purchase your SERIES 112 Kit and give one as a gift. 1. Place the order with your local distributor and request “Drop Ship from BIG KAISER.” 2. Mention promo code BOGO2019. The free kit will be sent to the school on behalf of you or your company, and you will be notified when the kit ships from BIG KAISER. Be sure to place your order before December 31, 2019, to benefit your local school.

Broadening their presence in Canada, GF Machining Solutions and GF Piping Systems will open a new joint headquarters to further strengthen direct sales and service support for Canadian manufacturers. The companies broke ground for the 67,000-square-foot facility located in Ontario, in late October of this year. The new Canadian headquarters will feature a 4,800-square-foot demonstration center along with full sales and service support staff that will ensure high responsiveness and application expertise. Also serving as a distribution center, the facility will streamline the sales and acquisition process for customers as well as help shorten delivery times. The joint GF Canadian Headquarters will be located at 41 Keyes Court, Unit 1, Vaughan, Ontario, L4H 2YZ Canada. According to John Giroux, country manager, Georg Fischer Piping Systems Ltd., Canada, the new GF facility will significantly benefit Canadian piping customers in terms of support and product availability.

OVENS & FURNACES

Exact Metrology offers $30 Challenge to Prove that the GOM CT Scanner is the Most Accurate Industrial CT Scanner on the Market The GOM CT scanner offers the highest accuracy and highest resolution of any 225kV system available today. Additional features include a 3k detector (3008 x2512 pixels), voxel size between 2 µm - 80 µm, photogrammetric calibration, and 5-axis kinematics, measuring area of Ø 240 mm, H. 400 mm, temperature balancing and I/O port. The GOM CT enables the inspection of complex parts based on volumes. All surfaces (including internal structures) can be used for shape and dimension analysis.

Exact Metrology is so confident in its ability to scan parts that it has issued the “GOM CT Challenge” to prove this. Any company that is considering purchasing a CT scanner can call Exact Metrology and validate the suitability, then send a part. All parts will be scanned and the images sent along with a $30 gift card to Best Buy. If you have any questions regarding the GOM CT Challenge, please call Steve Young from Exact Metrology at 513-815-4491.

Ipsen Expands Aftermarket Coverage in North America

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Ipsen USA announces the completion of an initiative to expand aftermarket services across the United States and Canada. Five Regional Sales Engineers (RSEs) were hired over the last six months to assist customers with replacement parts, retrofits, upgrades, service and technical support for any brand of atmosphere or vacuum heat-treating system. Ipsen’s RSEs have diverse backgrounds with experience in engineering, machine repair, and metallurgical processes. The RSEs are supervised by Matt Clinite, Ipsen Customer Service Sales Manager. The RSEs fill a crucial role within the organization by creating a more efficient system for managing customers’ needs and streamlining the process between new equipment sales, aftermarket service, and field support. Ipsen prioritizes innovative, industry-leading heat treating solutions and high-quality services. This new approach to

8 IMD DECEMBER 2019 Grieve-Q-122019.indd 1

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customer care will provide quick and easy access to experts in the field. With a network of more than 120 technicians, Ipsen has the largest service team in the industry.

Siemens expands SaaS offerings to Simcenter Amesim and Simcenter 3D Siemens Digital Industries Software announces the availability of Simcenter™ 3D software and Simcenter™ Amesim™ software delivered as a service. Through a strategic collaboration between Siemens and Rescale, a leader in enterprise big computing, engineers can now gain immediate, cost-effective software-asa-service (SaaS) access to high-end simulation tools. Particularly useful for small to medium-sized businesses, the SaaS framework offers new tiered product bundles in which customers can select the right level of capabilities they need, as well as monthly subscription-based billing and licensing and a pay-per-use

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quality matters.

Previously known as Motoman, Inc., the company was incorporated on July 18, 1989 as a 50/50 joint venture between Hobart Brothers Company and Yaskawa Electric America, and officially began operations on August 1, 1989. In 1994, Motoman Inc. became a wholly-owned subsidiary of Yaskawa Electric Corporation (Kitakyushu, Japan), a worldwide leader in mechatronics and robots. The company started with just 59 employees and now has nearly 700 employees serving from 11 strategically placed facilities throughout the Americas. Employees are committed to complete customer satisfaction and remain dedicated to delivering high quality innovative robotic solutions that help customers and partners compete globally. Yaskawa Motoman is also committed to supporting the nation’s STEM initiatives and promoting the use of robotics for education and workforce development.

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computing infrastructure. Large enterprises can also benefit from the availability of Simcenter on the Rescale cloud platform with multiple flexible licensing options available to solve specific business challenges. SaaS licensing can be used to add short-term software licenses in times of peak usage or bring your own licensing (BYOL) can be used to let Simcenter customers leverage their existing investments when high-performance computing (HPC) capabilities are needed.

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IMD 9

Talking Shop The more accessible we can make this technology, the more partners we’ll find who are interested in contributing to its advance.

FEATURING:

TALKING SHOP WITH: Dave Veisz — Vice President of Engineering, MakerBot I know that your North American operations are based in Brooklyn, New York. Give us an idea of your global footprint.

Our manufacturing facility is in Asia, where we also have quality control and test labs that are an extension of our R&D and quality labs in Brooklyn. All hardware and software engineering takes place in Brooklyn, and the teams work closely with the technicians in Asia on new product introduction into manufacturing. Being part of Stratasys is a huge advantage for us, as well, since we can leverage their vast engineering expertise in our own development efforts, whether that be new printer designs or developing industrial materials beyond the eight we’re currently able to process.

While the United States is our largest market, we are active globally, in countries including Germany, China, South Korea, Africa, Australia, and Mexico. We have warehouses, reps, and stocking distributors around the world. All of our printers are stock models, with the only customization having to do with selecting the appropriate “print mode” and the desired materials to utilize.

Looking at the four different printers you offer, could you outline in what way each model excels and/or differs, and who would benefit most from its capabilities?

We basically serve two primary markets: academia such as high schools, community colleges and universities, and professionals including engineers, architects, design firms, manufacturing, and industrial enterprises. With all of our printers we’ve concentrated on creating what we refer to as a “3D printing ecosystem,” where ease of use is just as important as the features the hardware and software provides.

The Replicator+ is our flagship printer for education, particularly the K-12 levels. Again, with our focus on the user experience we want the students’ introduction to 3D printing to be an accessible and welcoming experience, so we provide resources such as training, certification, and content to both the students and teachers to get the

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10 IMD DECEMBER 2019

most value and learning out of the 3D printing process. Our training not only focuses on how to use the printer and software, but also explains how to leverage 3D printing to learn design skills and problem solving.

As an aside, all of our printers are meant to be connected online so that updates are made automatically to keep everyone at the leading edge of new developments, and all mobile apps and print preparation software is free. The next level is the Z18, which is primarily for higher education and professional use, with a larger build volume.

Finally, we have the Method and Method X models, which we’ve invested a lot of focus and effort in developing over the past few years, optimizing them for the professional space. These printers are ideal for manufacturing facilities, machine shops, design studios, and other professional workspaces, including higher education applications in research facilities and test labs. We have seen a great deal of early adoption and are very proud of the results.

The goal was to bring many of the capabilities found in traditional industrial 3D printers into different workspaces in a way that’s accessible and easy to understand, allowing users with direct access to create industrial-grade 3D prints at an affordable price point.

What do you see as the benefits graduates of these additive manufacturing programs will bring to the industrial workspace?

They are profound. Think about what a recent graduate just entering the job market brings with them when they are equipped with these skills. Recent grads are the ones introducing 3D printing into the workplace, since they know the value from their experience in college fabrication labs, and we see that adoption throughout engineering and design offices happens quickly once they realize this value. So that’s why we’ve placed so much emphasis on accessibility, both in terms of price point as well as ease of use. The more accessible we can make this technology, the more partners we’ll find who are interested in contributing to its advance.

For more information please visit makerbot.com.

Business 4.0

Why Subtlety Is Critical to Organizational Change By: Andrea Belk Olson, MSC and CEO of Pragmadik

W

hen organizations examine ways to improve their culture and communications, they often look to the obvious.

Simplifying overly complex processes, eliminating redundancies, encouraging people to be more collaborative and so forth. However, for some reason, many organization's cultures end up changing only marginally or even not at all. The company's

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  DECEMBER 2019

leaders then search for alternative ways to increase productivity and positivity, whether it be high-level leadership training or employee engagement programs (i.e. parties). For a while, spirits improve, but things then fall back into the old groove.

I've seen throughout many organizational transformation efforts, an overly simplistic view of what truly impacts change. Leaders

examine and address the basic blocking-and-tackling elements, but frequently not the subtle things that influence the success or failure of initiatives like these.

Consider the idea of collaboration - the majority of leaders we talk to say that lack of collaboration is an obstacle to their organization's growth. So they put together cross-functional teams, create incubators, and "encourage" collaboration through broad communications such as newsletters and internal email campaigns.

The problem is, these are the basics - what is minimally required and expected to begin an organizational culture shift in this area.

But the deeper, more important aspects are the subtle elements that influence behaviors.

When we think of change, we often look to process, but what really impacts change is shifting individual mindsets through behaviors. For example, if you want your team to collaborate more or "better", simply providing them a space to collaborate and the permission to do so is not enough. It is essential to help individuals understand how they can effectively collaborate through clear example behaviors. It is essential to help individuals understand why collaboration benefits them - for the team, for the organization, and most importantly - for them personally. It is essential to help individuals understand how to become more open to new ideas and perspectives, through discussion facilitation and reinforcement.

While we often want to glaze over the process of culture development and change by simply dictating the behaviors we want to see, it's not half enough. The way to create lasting and

sustainable change is by creating a unified front to address the subtle aspects of change - influencing and reinforcing the right behaviors through guidance and representation - throughout the organization. Culture change isn't created, it's learned - and learning takes time. It takes repetition, and more importantly, it takes consistency.

When you're examining how to address your organization's challenges, look to the subtle elements that influence change.

Because the obvious ones you already know and are likely already implementing. So it is not about more of the same, but about addressing the underlying behaviors that truly shape culture - and sometimes they can be hard to spot.

ABOUT THE AUTHOR Andrea's 22-year, field-tested background provides unique, applicable approaches to creating more customer-centric organizations. A 4-time ADDY® award-winner, she began her career at a tech start-up and led the strategic marketing efforts at two global industrial manufacturers.

In addition to writing, consulting and coaching, Andrea speaks to leaders and industry organizations around the world on how to craft effective customer-facing operational strategies to discover new sources of revenues and savings.

Connect with Andrea to access information on her book, workshops, keynote speeches, training or consulting. More information is also available on www.pragmadik.com and www.thecustomermission.com.

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IMD 13

Safety & Maintenance

Improving Manufacturing Workplace Safety By: Tracy Skousen

I

mproving workplace safety not only promotes employee and customer wellbeing, but positions manufacturing organizations for long-term success.

According to the U.S. Bureau of Labor Statistics, in 2017 the manufacturing industry saw more than 300 work-related fatalities.

Further, out of every 100 workers, an average of 3.5 experienced an occupational injury or illness during the same year. These figures point to a workplace safety crisis in manufacturing, and should give pause to organizational leaders whose responsibility it is to protect the safety and wellbeing of their employees.

And while protecting human life and ensuring every employee is able to work in an environment free of health and safety hazards is a clear moral imperative, the compelling case for manufacturing leaders to strive for healthy and safe workplaces doesn’t stop there.

Considering that the industry contributes to economic growth at the highest multiplier of any sector — it is estimated that for every $1.00 spent in manufacturing, $3.60 is added to the economy — work-related injuries and fatalities in manufacturing equate to millions of dollars of lost productivity every year. In order

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14 IMD DECEMBER 2019

to guarantee their employees’ wellbeing and the health of their organizations’ bottom lines, it’s critical for leaders of manufacturing organizations to make workplace safety a top priority.

Achieving the Perfect Workplace Safety Score A major manufacturer with a number of branches across the globe, one Partners In Leadership client held a regional conference in which branch leaders came together to set safety goals and exchange strategies for promoting occupational health and safety.

At the conference, leaders of one branch of the organization declared that their new topline organizational goal was to achieve “Zero, Zero, Zero” — zero total recordable incidents, zero days away from work as a result of occupational injury or illness, and zero fatalities.

Upon hearing this declaration, other branch leaders in the room chuckled — some even claimed outright that such a goal was unattainable. Then, something unexpected occurred: an attendee in the audience raised his hand and said, “Actually, it’s not impossible — at one of our locations, we’ve achieved ‘Zero, Zero, Zero’ for three years running.”

The previously skeptical leaders of the other branches were so surprised to learn that this lofty goal was achievable that, upon returning from the conference, they began to share the story widely across their teams. The result? Employees across every level of the organization came to believe that Zero, Zero, Zero was a realistic goal toward which they all should be working.

The formation of this belief was crucial in mobilizing a change in behavior toward increased safety. This is because, according to the proven wisdom of The Results Pyramid, a proprietary Partners In Leadership model, beliefs serve as the foundational element of actions, which in turn generate results (which may end up being desired organizational outcomes or unintended consequences).

As such, when employees believed that Zero, Zero, Zero was possible, they acted in alignment with this belief, working to achieve the ideal of zero total recordable incidents, zero days away from work as a result of occupational injury or illness, and zero fatalities.

This story serves as a testament to the fact that curbing rates of work-related injuries, fatalities, and other adverse outcomes in manufacturing requires more than simply complying with state and industry standards (think: OSHA manufacturing safety regulations). In order to maximize safety in the workplace, organizational leaders weave the ideals of safety into the very fabric of their company culture.

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Making Workplace Safety a Cultural Priority It’s up to organizational leaders to implement changes in a way that reduces rates of work-related injuries, illnesses, and fatalities. To do so effectively, they must model desired mindsets and behaviors, empowering employees to recognize their beliefs and actions as vital elements in establishing a culture of safety in the workplace.

Leaders can follow these steps to achieve higher rates of safety within their organizations:

1: Establish Workplace Safety as a Key Result Even if safety is already a top organizational goal, solidifying it as a key result spotlights the objective and lays out more explicit expectations for employees. More than general goals, key results are an organization’s three to five meaningful, memorable, and measurable topline priorities that the organization must deliver on in order to be considered successful.

To kickstart an industry-wide safety revolution, manufacturing leaders must establish key results that are directly related to safety.

Zero, Zero, Zero is a great example. It is meaningful since it directly impacts employee wellbeing and the company’s revenue margins, it is memorable since it is articulated in a simple, catchy phrase, and it is measurable since its success can be easily quantified.

As Zero, Zero, Zero was, key results should be disseminated throughout an organization via top-down communication.

Every member of the organization — from interns and entry-level associates to C-suite executives — should be able to recite its key results at a moment’s notice.

2: Optimize Workplace Safety Protocols and Processes Before launching organization-wide training initiatives, leaders must ensure that safety protocols and processes are optimized for effectiveness and are likely to take hold throughout the organization.

Consider surveying all members of the organization in order to source honest opinions regarding the effectiveness of current processes. Exchanging and soliciting honest feedback from all employees not only promotes process improvement, but also conveys to employees that organizational leaders value their input, which in turn encourages greater employee engagement and accountability.

To develop the most efficient and effective safety protocols in the workplace, leaders must take it upon themselves to practice collaborative, creative problemsolving. Most importantly, the strategy driving this process must be aimed at shaping employees’ beliefs and behaviors in a way that catalyzes the achievement of safety-related key results.

— by telling success stories, celebrating employees who consistently model desired beliefs and behaviors, and more — they operationalize change from within by affecting employee mindsets. These experiences sow the seeds of a culture of safety.

3: Educate and Train Employees Around Workplace Safety

Leaders cannot assume their work is finished once they’ve trained their employees on safety best practices — or even after they’ve successfully established an organization-wide belief in the value of workplace safety.

Defined as the collective effect of the normative mindsets, values, beliefs, and behaviors that characterize an organization, company culture is constantly evolving, and thus requires attentive and ongoing management.

Leaders remain proactive about cultivating experiences for employees that demonstrate attitudes and actions that generate desired organizational results.

Once workplace safety protocols have been optimized to influence employees’ beliefs and behaviors, leaders can start rolling out training that enables their employees to put their vision into practice.

Leaders should craft training initiatives with the goal of creating meaningful experiences for employees, which, as The Results Pyramid explains, inform the beliefs they hold, which underlie behaviors, which ultimately drive results.

When leaders create powerful experiences for team members that foster the beliefs needed to improve safety

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IMD 17

When it comes to bolstering safety in the workplace, this means recognizing employees who go above and beyond to promote employee and customer safety, sharing inspiring stories of safety “wins,” and seeking regular feedback from all employees regarding the effectiveness of existing protocols and processes.

Reinforcing the Business Case for Workplace Safety Leaders position their organizations to meet benchmarks like Zero, Zero, Zero by following this roadmap: making safety a key result,

collaborating to improve safety protocols and processes, training employees to embody beliefs and take actions that promote safety, and actively managing company culture to maintain a focus on safety.

When manufacturing organizations prioritize the safety, health, and wellbeing of employees, distributors, and customers, they not only minimize work-related injuries, illnesses, and fatalities, but establish themselves as trustworthy organizations that value human life.

As a result, employees are more likely to exercise caution at every juncture of the manufacturing pipeline, which improves processes,

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18 IMD DECEMBER 2019

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increases operational efficiency, and ultimately strengthens Earnings Before Interest, Tax, Depreciation and Amortization, or EBITDA. What’s more, focusing on safety augments a brand’s message, generating greater brand trust, promoting high levels of employee and customer retention, and positioning the organization to enter new markets and expand its client base.

All these factors come together to lay the groundwork for high performance and sustained organizational growth. While optimizing workplace safety is crucial for guaranteeing the wellbeing of every

employee and customer, it also represents a unique opportunity for manufacturing organizations to improve operability and maximize topline performance.

ABOUT THE AUTHOR Tracy Skousen is senior partner, president International Division, and senior vice president of the Accountability Business Unit at Partners In Leadership. Learn more at partnersinleadership.com.

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IMD 19

Manufacturing Showcase

MANUFACTURING SHOWCASE

Innovakote By: Russ Willcutt

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20 IMD DECEMBER 2019

IMD – The Industry’s Most Extensive Industrial Publication

I

n metalworking, depending on customer specifications and the part’s intended end use, there is often a finishing process of some kind involved.

This can be everything from specialized surface finishes to coatings providing protective and wear-resistant attributes to the part. During some of these processes — as is often the case with anything in manufacturing — there is a certain amount of waste material involved. When applying powder coatings to metal parts, for instance, whatever powder isn’t left on the part generally goes straight to the landfill… basically paying someone to throw your material investment out the window.

One company has found a way to reuse the waste in the powder application process, The company is called Innovakote West Michigan, LLC, based in Kent City, Michigan, and it has come up with an ingenious process for recycling powder remaining after the application process, and then reselling it to manufacturers at significant savings, thereby creating a “closed loop” system that’s good for the environment, might help protect against any future dumping litigation, and strengthens a company’s bottom line by lowering powder purchase costs.

As for the application process, powder is an environmentally friendly substitute for liquid paints, which contain volatile organic chemicals (VOCs) that are released into the

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IMD 21

atmosphere during curing. When applying powder to metals, an electrostatic charge is first introduced into the substrate, with a gun then applying the powder to the surface of the part. The charge actually draws the powder to the surface, which is ideal for parts with deep channels or complex geometries. The part is then cured in an oven at 400 degrees F for 10 or so minutes, releasing no VOCs. Powder application systems automatically gather waste powder, which is then packaged in drums and carried away by waste services headed straight to the landfill.

With Innovakote — now in its final development stages, developing powders per customer specifications — a new model has been developed.

It is partnered with an existing company, Surplus Coatings, which has been in business since 1995. Dwayne Behrens is the owner of Surplus Coatings, while he and Brian Spicer are co-owners of Innovakote. The relationship between the two companies is that Surplus Coatings already has a successful business with an extensive customer base gathering waste powder to be remanufactured, which it then supplies to Innovakote for recycling into new powder that customers can purchase.

“The recycled powder is remanufactured to meet each customers specifications, and is available in a variety and finishes” says Behrens. “Innovakote specializes in manufacturing powder coating by utilizing up to 95% recycled raw materials.”

The larger concept, as mentioned, is to create a closed-loop system where materials that were previously treated primarily as waste are now utilized and returned to the manufacturing process, while at the same time lowering the cost of the finished product. “We see this as an environmentally friendly

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22 IMD DECEMBER 2019

cycle in which everyone benefits,” Spicer says, “and it eliminates any ‘cradle to grave’ concerns powder users may have had about how the material was disposed of in the past.”

With a global customer base, Surplus Coatings is familiar with disposal regulations around the country and world. Some areas of the United States require special permits, as is the case in other countries as well. The partners see this as a growing trend. So with

an estimated 1.8 billion pounds of petroleum-based products slated for disposal in landfills around the planet this year, the timing is right to develop and present solutions to the industrial market.

“We’re doing our part to advocate for a circular economy that eliminates waste in the powder coating industry,” Behrens says.

Learn more by visiting innovakote.com and surpluscoatings.com.

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IMD 23

Workforce Development

Build a Multigenerational Workforce to Address Today’s Skills Gap By: Jeannine Kunz, Vice President of Tooling U-SME

I

ndustry 4.0 is transforming manufacturing. While companies work to integrate smart manufacturing into their operations, manufacturers of all sizes look and compete for scarce skilled talent to fill their workforce pipeline. Not only do manufacturers need to keep up the skills and capture the intellectual and institutional knowledge of their incumbent workers, they also need to draw in younger generations entering the workforce.

This generational diversity is driving a cultural shift as dramatically

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24 IMD DECEMBER 2019

impactful as the technological shift underway. And if your company isn’t yet prepared to accommodate this cultural transformation, you’re behind: The time to prepare your business and adjust your culture is now.

As advanced technologies such as robotics and artificial intelligence, cybersecurity and additive manufacturing take center stage, workers of several generations are vital to the success of manufacturing enterprises.

IMD – The Industry’s Most Extensive Industrial Publication

How do we merge this multigenerational workforce and build cohesive and effective teams to make this cultural transition seamless?

For the first time, the manufacturing workforce comprises five generations — at once! On the shop floor, you may find workers from the silent generation (in their 70s poised for retirement), baby boomers, Gen Xers, millennials and the rising generation of Gen Z, with the oldest turning 22 this year.

Bridging the generation gap can help businesses address the workforce skills gap, because this cross-pollination of diverse thought, experience and approach strengthens their workforce and their business. In addition, broader diversity of age, race and gender creates different perspectives. While sometimes uncomfortable, this broad spectrum helps drive innovation, productivity and growth.

If done right, companies will benefit from wide-ranging ideas and information that come from such a broad group of people, and employees will feel that their job and contributions matter.

Recommended solutions to the challenges inherent in this new multigenerational workforce are recruiting the right people, retaining incoming talent with new onboarding processes that include career pathways and providing a structured training program that can benefit everyone of all ages. Without leadership’s understanding of and commitment to making this cultural shift, manufacturers could be affected by annual turnover of up to 20-percent or higher.1 With leadership’s buy-in, 70-percent of those employees who quit might have been retained.2 Tooling U-SME’s new report, “6 Ways to Build a Cohesive Multigenerational Manufacturing Workforce: Prepare for the Future – Now” has identified steps manufacturers can take to bring their cross generation of employees together, so they can benefit from the skills and knowledge of all:

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When guidelines and expectations around values and behaviors within a company are clear, all generations thrive. Accountability becomes the benchmark for success — no matter what age the employee. Building a team of growth-oriented, diverse individuals encourages well-trained workers to learn from each other, build on different ideas and create new ones.

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Foster Communication It’s important to teach communication skills to help people get along, respectfully. In fact, older generations can be a valuable resource for helping younger generations build interpersonal skills.

To thrive, a company needs to provide generational training, highlighting the value of each generation so they can communicate better. Training all employees on the generational differences and similarities will make a more cohesive environment.

Younger employees have gained a reputation for being vocal and making their expectations obvious; however, it’s equally important

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IMD 25 8/13/19 11:31 PM

to hear what older generations think. How would they suggest integrating early-career colleagues? Externally reinforcing the unique assets of each team member is also part of a leader’s job, and an important step in building a cohesive multigenerational team.

Create a Collaborative Environment At their core, people want similar things.

They want to be engaged. They want to feel valued. They want to grow and develop.

Work styles may vary, and communication styles may differ, but creating a collaborative environment where all employees across the company have a chance to interact will break down stereotypes and misperceptions.

Here are some ideas for building connection and camaraderie among employees: » Create comfort zones for people to sit and talk » Give five-minute “social” breaks so workers can sit in these areas and check their social media » Start an engagement team to plan company activities such as working at a pet shelter or creating a food drive for the homeless » Introduce a mentorship model pairing a veteran employee with a younger employee, providing a reliable resource for insights about the company

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26 IMD DECEMBER 2019

Provide Regular and Immediate Feedback Companies are adopting a new model for providing job performance feedback. This doesn’t have to be a long session. Just five minutes of clear, direct feedback on a regular basis will keep workers motivated and engaged.

Quarterly performance goals are far more practical for today’s business environment and are a more accurate reflection of employees’ overall performance. This approach may be surprising to long-term employees, but they will also benefit from quick feedback and will appreciate the opportunity to give it. Everyone

will rejoice when they see that positive reinforcement through incentives is part of the package.

Build a Formal Training Program Manufacturers can outline each step for an employee to reach the next career level, whether that level is a toolmaker or an engineer.

Offering ongoing learning opportunities for all employees boosts their confidence and interaction while building loyalty, morale and productivity.

Ensure All Feel Invested in the Company All generations want to share ideas and show what they can do — they may just approach it differently. Ensuring workers of all ages feel they are part of an important mission builds a cohesive and collaborative environment, while boosting quality, safety and productivity.

There’s no more time for debate about the new generation of workforce employees or preconceived notions of their profiles. At their core, people want similar things — to be engaged, feel valued and grow and develop during their careers. By adopting a fresh attitude and being flexible with new processes, manufacturers can expect different perspectives from younger generations, encourage collaboration with incumbent workers through a mentoring initiative, increase engagement through open dialogue with workers and management, and enhance productivity and growth.

Millennials and members of Gen Z represent our greatest opportunity to address the talent shortage in the manufacturing

industry. These younger generations bring to the table an abundance of technology expertise and an eagerness to be involved, and they can inspire a new point of view toward building a cohesive work environment.

Leveraging the unique strengths of each generation and enabling them to learn from each other creates a more collaborative and engaged environment. When employees in general have more opportunities to learn at work, their engagement, productivity and overall happiness increase.

To learn more about building a cohesive multigenerational workforce, download the full “6 Ways to Build a Cohesive Multigenerational Manufacturing Workforce: Prepare for the Future – Now” report available at ppc.toolingu.com/multigenerational

ABOUT THE AUTHOR: Jeannine Kunz is vice president of Tooling U-SME, a leading provider of learning and development/training solutions for the manufacturing workforce. jkunz@sme.org

SOURCES: 1. Tooling U-SME Industry Pulse: Manufacturing Workforce Report.

2. 2018 Retention Report: Truth & Trend in Turnover, Work Institute.

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IMD 27

New Technology

Can Augmented Reality Improve Manufacturing?

M

ore than two centuries ago, German philosopher, Immanual Kant, described virtual reality as existence within our minds, rather than the physical world.

Today, virtual reality is an established technology that has been deployed in various industries including gaming, marketing, and manufacturing. But, what about augmented reality? Mark Howard, US country manager of industrial parts supplier EU Automation, investigates its potential.

Augmented reality describes a digital enhancement to the external world. A good example of this would be Nintendo’s Pokémon Go app, which overlays images of characters onto the real world, through the user’s mobile phone screen. There are several popular examples of successful augmented reality. However, many of these have been for gaming or novelty applications.

In the manufacturing realm, most applications for augmented reality are still in their infancy, but they do have great potential. The

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beauty of augmented reality is the ability to present much more than digital characters or images. Using the technology, you can also overlay instructions, statistics, and information. For example, looking at a piece of equipment through an augmented reality device could overlay important data related to it, such as its current performance, output, and temperature.

Microsoft’s HoloLens mixed reality headset, a combination of augmented and virtual reality technology, has already been deployed in some manufacturing facilities for this reason. However, some of the most beneficial areas of its use are to help solve problems related to maintenance.

Let’s say a piece of manufacturing equipment is broken.

Using a mixed reality headset, a technician could simultaneously examine the physical parts of the machine, while also viewing text, instructions, and images to help them to fix the problem. For example, the information that technicians need when checking or

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repairing an industrial motor can be projected directly on the part they are operating on. This eliminates the need to consult charts and instruction manuals, speeding up the process. Moreover, the information projected guides the operator chronologically, so that even a relatively unexperienced worker can perform the necessary repair.

This is particularly advantageous for complicated pieces of equipment or facilities with few experienced personnel. In these instances, augmented reality can be used to deliver expert support remotely from the original equipment manufacturer (OEM), without needing to fly specialists from one side of the globe to the other.

Industrial robots provide a good example of this flexibility.

Let’s imagine a six-axis robot has malfunctioned, but there are no employees with the expertise to fix it on site. Using a headset for remote maintenance would allow any employee with an augmented reality device to be guided by a specialist. For instance, the robot manufacturer based in Japan.

The expert will then provide support by simulating the actions the employee should perform. This technique can also be used to train new employees — a valuable tool considering engineering’s current skills shortage.

In fact, training new employees is one of the most valuable areas for augmented reality in manufacturing. One of the biggest

30 IMD DECEMBER 2019 IMD-Q-072019.indd 1

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challenges on onboarding a new member of staff is ensuring that the employee is aware of the correct protocols and procedures.

Uncertainties can lead to safety issues, particularly in processing industries with dangerous operations.

In this instance, a mixed reality headset may not be appropriate because these are usually designed like virtual reality headsets and can, therefore, be obstructive and distracting. A smaller device, such as a tablet, mobile phone or pair of digitally enhanced glasses, would be ideal.

Let’s say a new starter has been put to work to operate a piece of processing equipment, such as a furnace, that they have never used before. Using augmented reality technology, the device could automatically provide machine data to help them to complete the task correctly and safely. For example, delivering alerts if the machine is outside of the specified temperature range.

Jaguar Land Rover has already demonstrated the potential of augmented reality for training purposes, in a joint project with Bosch and its REFLEKT ONE software system. The project developed an application that digitally visualized an ‘X-ray’ onto the dashboard of some of its vehicles. Using the technology, the app allowed technicians to see everything in operation behind the vehicle’s paneling. This removed the need to remove and reinstall the dashboard, simplifying training and saving on costs.

It has been two centuries since the potential of augmented and virtual realities were envisioned. However, it is only recently

that the technology is coming to fruition for manufacturing.

While it’s applications in industry may not be as novel as catching Pokémon, the technology is set to make a significant impact on training and maintenance.

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IMD 31

Process

Utilizing Live Tool Speed Increasers

Minnesota CNC shop uses Heimatec speed increaser to up RPM and feed rate; significantly reduces cycle time on aluminum engraving application

K

urt Machining (Minneapolis, Minnesota) specializes in providing precision CNC machined parts, using state-of-the-art technologies and up to 5-axis machining. Since 1952, this 110,000 sq. ft. shop has provided its customers in a variety of high-quality demand markets with components and welded assemblies.

These include aerospace, defense, semiconductor, energy, automotive and more. A very flexible shop, Kurt produces parts ranging from micron-sized semiconductor components to 2000 lb. workpieces for the defense sector.

On a recent project, where 5000 pieces of 6060 aluminum were to be engraved on a Hwacheon horizontal turning center, Kurt Engineering Manager, Shawn Eisenshank, had concerns over the cycle times. He turned to Heimatec speed increaser, supplied to Kurt by Platinum Tooling, the exclusive importer of Heimatec live tools for his local tooling distributor, Abrasive Specialists, North America, provided a 9X cost savings for the shop on an engraved 6060 aluminum component.

Inc. (ASI) and their tooling partner, Platinum As Shawn Eisenshank notes, “This is one of those classic scenarios, Tooling, for suggestions. Leigh Kinnan of ASI worked with the where the theoretical has proven out in practice, as we’ve seen exactly local Platinum Tooling representative, Cody Papenfus, to test run the results ASI and Platinum Tooling proposed in their test calculations.” a Heimatec speed increaser, with the goal of increasing RPM on Cody Papenfus of Hexis in Plymouth, Minnesota, who is the the machine and decrease part cycle time, with a documentation area rep for Platinum Tooling adds, “We say we put our expertise to of the potential savings. After performing the calculations in work at the spindle of the machine and, in this case, that’s exactly consultation with Preben Hansen, president of Platinum Tooling what happened. The speed increaser performed as expected, the and exclusive importer for Heimatec products in North America, it customer got the results promised and it was a win-win, for all. We was determined a significant savings could be realized. serve our customers for the long haul and successes like this one are Detailing the application, ASI demonstrated that a 1:3 speeder, the big reason.” increased the spindle RPM enough that when coupled with the Kurt Machining performs both vertical and horizontal milling nearly three-times increase in the feed rate on the machine, would and turning, complex assemblies and weldments, delivering with produce a significant improvement to the current machining cycle. rapid lead times. CAD compatibility is offered for web-based Calculating the reduction in machining cost per part and factoring communications and fully interactive manufacturing engagement the cost of the speed increaser, it was determined the use of the for its customers. The company performs contract manufacturing Heimatec product onboard the Hwacheon turning center would in high quantity as well as prototyping for new designs. Kurt also result in a nine-times cost saving for the customer, in the first year’s performs impact extrusion, heat treating and cleanroom operations production run on this engraved aluminum component.

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32 IMD DECEMBER 2019

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TOP QUALITY HOIST RINGS AND RIGGING ACCESSORIES including ultrasonic cleaning of stainless steel and aluminum components and assemblies, with cleaning to Class 1000 with 100 protocol. The company is ISO 9001:2015 and AS9100D plus NADCAP Certified. Kurt Machining is quality certified by the U.S. Government to MIL-Q-9858 and MIL-I-45208.

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IMD 33

Industry Insight

Improving Performance with Hand Tools

Chicago Pneumatic CP3550 series expands to meet all industrial grinding and sanding needs

W

ith the addition of nine new products, Chicago Pneumatic has created a comprehensive range of grinders and sanders meeting managers’ need to increase productivity while offering operators comfort. Its expanded CP3550 series promises high-quality finishes with minimal effort, thanks to powerful and easy-to-handle metal-working tools offering intensive industrial durability at an accessible price.

“The expansion to a 17-model range allows perfect matching of applications and tools,” says Harald Odenman, product marketing manager at Chicago Pneumatic. “These innovative products score highly over competitors in terms of performance and ergonomics.

Their superior power creates greater torque for faster material removal rates, making users more productive. Efficiency is further boosted by easier tool handling and control, with better comfort. This allows fast, precise work and reduces operator fatigue.”

The New Additions A 6-inch angle grinder has been added to the existing five models with 4-to-5-inch wheels. Four new die grinders – two standard and two extended – join the previous angle die grinder. These come complete with an Erickson 200 collet for attachment of ¼-inch and 6-millimeter mounted points and carbide burrs. The two current 5-inch angle sanders are now complemented by two new tools for use with 7-inch abrasive pads.

The other two additions are low-speed sanders, whose gearboxes generate high torque with reduced speed (3,000 rpm) for polishing or delicate applications. They operate with 7-inch or 9-inch sanding wheels or flapwheels and, like the angle sanders, give a choice of models with 5/8-inch or

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34 IMD DECEMBER 2019

M14 shaft threads. Designed primarily for high-output work environments like foundries, casting plants, fabrication shops, and shipyards, CP3550 series tools are also ideal for production and maintenance operations involving cast iron, steel, stainless steel, aluminum, alloys and composites.

Typical tasks include deburring, contouring, chamfering, fettling, weld seam removal, surface preparation, cleaning, polishing and finishing.

Delivering High Power The CP3550 series with its 1.5 hp, 1100 Watt governed motor delivers high power compared to many direct competitors. In tests against those products, material removal rates using CP3550 tools were over 50 percent higher – and in one case over 80 percent.

Advanced features on all models include a rotating inlet swivel – found on no other comparable tool at this power level – which enables free maneuvering and avoids hose knots. The streamlined safety lever found on each tool can be operated comfortably, even in thick gloves, and is easily directed downwards. Small diameter handles give a comfortable grip, while a thermally insulated composite over-sleeve avoids the discomfort of handling cold tools over long periods. Meanwhile, unique silencer foam technology reduces noise emissions.

Downtime for accessory changes on CP3550 angle grinders and angle sanders is reduced by a fast and simple spindle lock feature

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requiring just one wrench. Keyless angle grinder guard adjustment – unique amongst direct competitors – enables quick changes, even when wearing gloves, to suit different work positions and to deflect sparks safely.

A Complete Range For High-Quality Finishes With Minimal Effort “With CP3550 series tools you get a lot of power, performance and ergonomic features at an affordable price,” says Odenman. “They also save on operating costs, thanks to a 1,000-hour maintenance interval and a tough construction designed for long life and reliability in demanding industrial applications. Best of all, you can now meet all your grinding and sanding needs through one complete range of compatible pneumatic tools which give you a great finish quality with great ease.”

ABOUT CHICAGO PNEUMATIC Since 1901, the Chicago Pneumatic name has represented reliability and attention to customer needs, as a global manufacturer of power tools, air compressors, generators, light towers, and hydraulic equipment for professional and industrial applications. It represents products that are engineered for high performance. In addition to pioneering design, high-impact technology and durability, Chicago Pneumatic means customer value. Chicago Pneumatics’ team of people start every single day with a passion to research, develop, manufacture and deliver new products that are meant to meet your needs not only today but tomorrow as well. Chicago Pneumatic has consistently practiced their brand promise — People. Passion. Performance. At Chicago Pneumatic, our goal is to deliver best-in-class global service and local support to our vehicle servicing, industrial and construction customers through a dedicated product portfolio and a strong network of authorized distributors.

For more information, visit www.cp.com

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

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

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IMD 35

On Exhibit

PRI TRADE SHOW DATES: DECEMBER 12 – 14, 2019 Location: Indiana Convention Center | Indianapolis, Indiana Held December 12-14 at the Indiana Convention Center in Indianapolis, the 2019 PRI Trade Show will feature over 1,100 companies exhibiting in more than 3,300 booths and showcasing the latest products, services, machinery, simulation and testing technologies, and trailers for the racing industry in a single location. Now in its 32nd year, PRI encompasses all forms of racing and attracts attendees from all 50 states and all over the world, including professional race teams, retail shops, warehouse distributors, engine builders, fabricators, dealers, and installers.

For more information, visit performanceracing.com

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

BOOTH: 5507

The Original” Dynafile® Air-Powered Abrasive Belt Tool The world-famous Dynafile® from Dynabrade replaces tedious hand filing and sanding. Grind, deburr, blend, polish, finish and more. Grind from contact wheel or platen pad. Finish and polish using slack of belt. For use on metal, plastic, fiberglass, composites, rubber, glass and stone. The motor easily adjusts to the most comfortable throttle lever position. Superior belt tracking permits use of 1/8-inch, ¼-inch or ½-inch wide x 24-inch long abrasive belts. The Dynafile allows for work in areas as small as 3/8-inch diameter. Lightweight composite belt guard allows quick and easy belt change. Hard and soft platen pads mount onto contact arms for heavy grinding or contour polishing. » For more information, visit www.dynabrade.com BOOTH: 5659

BIG KAISER Offers New Chip Blower for Cleaning Parts and Tables BIG KAISER has introduced a new Chip Blower designed to make removing chips and coolant from parts and machine tables fast and easy.

The Chip Blower automates in-machine cleaning of coolant and chips by delivering high-volume air flow with spindle rotation. When not in use, the Chip Blower fits easily into any automatic tool change system for vertical, horizontal or multi-tasking machining centers. The Chip Blower can be used with automatic tool changers and programmed into a machining cycle, helping to improve machine utilization and increase productivity. The Chip Blower complements the solid construction, fixed blade ChipFan that was introduced two years ago. » For more information, visit www.bigkaiser.com

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36 IMD DECEMBER 2019

IMD – The Industry’s Most Extensive Industrial Publication

IF YOU HAVE AN EDGE… WE HAVE A TRIM! BOOTH: 5311

Next Generation RSF Kit Angle Encoder for Motion Feedback RSF Elektronik is now offering a next generation kit angle encoder for motion feedback best suited for applications in robotics, semiconductor, medical and machine tool. Offered through parent company HEIDENHAIN CORPORATION in North America, this new encoder is available in both absolute (MCR 15) and incremental (MSR 15) versions. Both models consist of an optical scanning unit and a separate full circle drum with the graduation on the outer diameter. The new absolute MCR 15 and incremental MSR 15 encoders are available in several sizes of drums, from an inside diameter of 40mm up to 330mm.

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» For more information, visit www.heidenhain.us/ BOOTH: 5117

The POWER MIG® 360MP Welder Takes a Giant Step Forward Lincoln Electric® has taken the next evolutionary step in POWER MIG welding technology with the introduction of the POWER MIG 360MP welder. This professional-grade machine combines an easy-to-use interface with a number of advanced welding features. The result is a multi-process workhorse, ideal for metal fabrication, maintenance and repair, auto body and light industrial applications. Designed with a 7-inch color display to facilitate smooth communication between operator and machine, the POWER MIG 360MP welder is capable of Stick, TIG, MIG and Flux-Cored welding. » For more information, visit www.lincolnelectric.com

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IMD 37

BOOTH: 5249

Mastercam 2020 Comprehensive Turning Software From accepting and programming any CAD file to Dynamic Motion™ roughing and precision finishing, Mastercam 2020 Lathe gives you a variety of options to turn all your parts exactly as you need them.

Mastercam 2020 Lathe features new 3D tooling, filters for inserts and holders, improved chuck jaw definitions, and much more.

A few enhancements include support for pie-shaped jaws in additional to rectangular-shaped jaws, ability to change the mounting orientation with easily reversible steps, as well as a live preview showing the overall shape of the jaws and total dimensions. » For more information, visit www.mastercam.com BOOTH: 5529

Miller Introduces Supplied Air Respirator for T94i-R™ Series Welding Helmets The Supplied Air Respirator (SAR) is lightweight and versatile, with a C50 Air Regulator that can cool air entering the welding helmet up to 50 degrees Fahrenheit. It can be paired with the new BreatheAir™ Filtration System. When paired with a T94i-R helmet, the SAR system provides the same benefits as the Powered Air Purifying Respirator (PAPR) helmet accessory from Miller — with the added ability to cool the air entering the helmet. These cooling capabilities are especially beneficial for manufacturing operations located in high heat and humidity climates. » For more information, visit www.millerwelds.com BOOTH: 5561

Auto Start Dust Extractor Pedestal from Palmgren Designed for factories and shops that require immediate dust filtration, Palmgren’s Auto Start Dust Extractor Pedestal eliminates dust in the workstation. This compact extractor creates a safe work environment by capturing grinding and deburring dust at its source. The dust collector features a 2-inch port connection with a dual port adapter with two 2-3/8-inch ports. Palmgren’s Auto Start Dust Extractor Pedestal returns clean air to the workplace with its self-contained filtration system that efficiently. Now observing its 100th anniversary, Palmgren is a C.H. Hanson brand. » For more information, visit www.palmgren.com BOOTH: 5129, 5139, 5229

Heavy Duty Cylinder Head Valve Seat and Guide Machine The Rottler SG80A was created specifically for machine shops that rebuild small to large cylinder heads found in the heavy-duty engine industry.

Large cylinder heads come in many shapes and sizes, from 24 valve single casting cylinder heads to huge single cylinder heads used in natural gas, mining and marine workboat engines. Over the decades, Rottlers spindle design has proven that their engine block machines are able to "plunge cut" wide counterbores found in large engine blocks with exceptional results. » For more information, visit www.rottlermfg.com

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38 IMD DECEMBER 2019

BOOTH: 5101

SV-15 from Sunnen The SV-15 is a versatile automatic cylinder hone capable of handling bore diameters from 0.750 inches to 8 inches (19-203 mm) and lengths up to 11 inches for all types of blocks, from singlecylinder and high-performance engines to diesel truck and industrial blocks up to 46 inch long.

The SV-15’s standard multi-position rollover fixture handles inline and most 60 degrees/90 degrees V-type automotive blocks, and the optional CK-6200 clamp kit expands the range of blocks that can be accommodated. With separate spindle and stroker motors – 3 hp/2.25 kW and 1 hp/ 0.75 kW respectively – the SV-15 can run standard Sunnen tools as well as the DH-series diamond hone head. » For more information, visit www.sunnen.com BOOTH: 5343

TRUMPF Digital Assistant For Sheet Metal Fabrication Using a tablet, machine operators and assembly workers can browse information designed to make their daily work easier – from advice on setting up machines to recommendations on how parts should be packaged. By ensuring people can always access the key information they need without having to search for it, this software solution saves time and helps both experienced and untrained employees work independently and efficiently.

Workmate will be available from spring 2020. Workmate helps users organize their day’s work more efficiently by providing a list of all pending jobs. It also offers a dedicated user interface for preparing jobs. » For more information, visit www.trumpf.com

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IMD 39

Product Showcase

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

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

New Anti-Static Air Knife with 30% Better Performance is CE, UL and RoHS Certified EXAIR’s new Gen4 Standard Ion Air Knife eliminates static electricity 30 percent better at low inlet pressures which saves compressed air and money. Production speeds, product quality and surface cleanliness can improve dramatically. It eliminates static on plastics, webs, sheet stock and other product surfaces where tearing, jamming or hazardous shocks are a problem. Gen4 products have undergone independent laboratory tests to certify they meet the rigorous safety, health and environmental standards of the USA, European Union and Canada that are required to attain the CE and UL marks. They are also RoHS compliant. New design features include a metal armored high voltage cable to protect against abrasion and cuts, integrated ground » For more information, visit www.exair.com

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40 IMD DECEMBER 2019

connection and electromagnetic shielding. The Gen4 Standard Ion Air Knife incorporates EXAIR’s Standard Air Knife that minimizes compressed air use by inducing surrounding airflow at a ratio of 30:1.

The unique amplified airflow carries the ions to the target, making it possible to eliminate static charges in less than a half second. Air volume and velocity are infinitely controllable from a “breeze” to a “blast” to gently wipe or forcefully blow away debris.

EXAIR’s Gen4 Standard Ion Air Knife product line is available from stock in 3 inches to 48 inches long. The electrical ion source is shockless and there is no radioactive element. A new selectable voltage power supply has been designed to operate Gen4 products.

IMD – The Industry’s Most Extensive Industrial Publication

More Versatile Long-Grooving

DEWALT Enhances Three Original 60V MAX FLEXVOLT® Tools DEWALT announces upgrades to three products that were part of the original DEWALT FLEXVOLT® System, debuted in 2016. The new 60V MAX* FLEXVOLT® 7-1/4 IN. Circular Saw (DCS578), 60V MAX* FLEXVOLT® 4-1/2 – 6 IN. Grinder (DCG418), and 60V MAX* FLEXVOLT® Reciprocating Saw (DCS389) each offer increased power versus their predecessors. Each of these tools achieves this increase in performance via new motors, new software, and new controls. In addition, each of these tools will be available as a kit with a 9.0Ah battery. When 60V MAX* tools and the FLEXVOLT Battery System debuted in 2016, they revolutionized power tools, featuring the world’s first batteries that automatically changed voltage when the user changes tools.

The Dormer Pramet parting-off and grooving assortment as grown with the additions of a new insert, two new geometries, a grade, blades and tool holder. The new 0.98in GL double-edged insert is available in a variety of widths from 0.08 – 0.236-inch. Targeting long-grooving applications, GL supports 60-percent capacity over the existing LCMF16 insert. A PVD grade, G8330, has been introduced for the GL insert to provide a versatile and stable option when machining steel, stainless steel and cast iron. The insert is also supported by two new geometries. Its cutting-edge strength resists cracking when grooving interrupted cuts and is ideal for the parting-off of bars. » For more information, visit www.dormerpramet.com

» For more information, visit www.dewalt.com

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IMD 41

RND Automation Leverages Epson Robots for Unique Hydraulic Valve Assembly Solution RND, a Platinum level Epson AutomateEliteSM System Integrator partner, incorporates the Epson SCARA and 6-Axis robots with rotary and linear indexers and machine vision for its Hydraulic Valve Assembly Machine, a turnkey solution for the most demanding assembly operations. RND chose the Epson T3 All-in-One SCARA robot for its fast installation, low cost, and all-in-one design, with a built-in controller, perfect for simple pick and place operations, and the G3 SCARA robot for its increased speeds and inertial loads for the more demanding stations. The Epson C8 6-axis robot features a compact wrist for efficient motion in tight spaces and a compact elbow for optimum workcell layout. » For more information, visit www.epson.com

Collaborative Arc Robots FANUC’s new collaborative arc welding robots offer the same high level of performance that FANUC ARC Mate robots are known for including world-renowned technology and proven reliability. A built-in sensor allows the welding cobot to work safely alongside people without the need for expensive guarding. Easy to use – even for those who have never used a robot, FANUC’s arc welding cobots are equipped with FANUC’s ArcTool application software. ArcTool’s easy programming interface supports both simple and complex applications, including FANUC's advanced features such as Weaving, iRVision, Seam Tracking, Thru-Arm Seam Tracking (TAST) and Multi-pass. Both of FANUC’s new welding cobots provide six axes of motion for maximum flexibility. » For more information, visit www.fanucamerica.com

char-lynn hydraulic products low speed high-torque motors… The Char-Lynn

motor range consists of three major types based on the valving used to distribute fluid through the Orbit gear set (geroler or gerotor), Spool Valve, Disc Valve and VIS (Valve-in-Star). A variety of displacement sizes are available in each of the three motor types to provide a wide range of speeds and torques.

steering control units… offer these advantages: • Minimal steering linkage reduces cost, provides design flexibility.

• Complete isolation of load forces from the control station.

• Continuous, unlimited control action with low output torque.

• Wide selection of control circuits and meter sizes.

• Works with many kinds of power steering pumps or fluid supply. gear pumps… Eaton Series 26 gear pumps with 13-tooth gears minimizes flow ripple to reduce noise and vibration.

Bearing lubrication system uses inlet oil rather than high pressure oil, improving volumetric efficiency and power output. The 13 available displacements and many mounting configurations provide for an easy retrofit. Other series available.

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42 IMD DECEMBER 2019

Festo Now Distributing Magswitch Magnetic Gripping and Clamping Solutions Festo now offers Magswitch switchable magnetic gripping and clamping solutions to automotive and original equipment manufacturers (OEMs) through a new distribution agreement.

Magswitch automation solutions are designed to last the life of a production line. The company has shown that energy costs can be lowered by as much as 90 percent, throughput can be increased by up to 30%, and capital costs reduced as much as 25 percent compared to systems using vacuum cups and pneumatic/electric grippers or clamps. Magswitch offers single sided gripping systems featuring true on-and-off magnetic technology that can significantly simplify and lower costs of complete automation systems. » For more information, visit www.festo.us

Rust Proof Chemical Resistant Island Canopy Hoods Island Canopy Hoods are ideal to locate over peninsulas and are designed to collect and exhaust corrosive vapors, heat, steam and odors when mounted over areas with water baths, hot plates or portable equipment. Manufactured of molded one-piece composite resin, canopy hoods are lightweight and can be wall-mounted or suspended from the ceiling. The canopy fume hood’s glass smooth surfaces provide superior chemical, corrosion and heat resistance.

Optional side panels prevent cross drafts and further improve airflow while providing a way to contain chemical spills. » For more information, visit www.hemcocorp.com

New AccuLock™ R Series Consumables Increase Throughput and Efficiency Tregaskiss has designed its new AccuLock R Series Consumables to virtually eliminate cross-threading issues and offers AccuLock HDP Contact Tips as an option within the series to extend tip life by 10 times or more in certain pulsed welding applications. The consumables can help to reduce both unplanned and planned downtime in robotic MIG welding applications. By increasing efficiency, AccuLock R Series Consumables help companies achieve annual cost reduction and throughput goals — with minimal risk or effort. They are ideal for applications in the automotive, fabrication and manufacturing industries. » For more information, visit www.tregaskiss.com

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• Can be adapted to many other applications • 120 Volts • On/Off switch • Up to 50,000 hours life • Flexible goose neck keeps the light where you need it • Double shade design permits fast heat dissipation • Energy savings

Important Information! It is a very bright LED light for work benches, milling machines, lathes, drill presses, etc.It can also be adapted to fit other machines and applications. Just tap 2 holes anywhere it’s convenient and mount. The LED will be much cooler than Halogens and use less than 1/4 of the electricity.

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IMD 43

Mitsubishi Electric and ASTES4 Offer First Fully Integrated Laser Automation Solution The ASTES4 multifunctional system is the first fully integrated solution capable of controlling the entire production process from loading, cutting, sorting, and unloading through to the storage of finished parts. The system utilizes four cartesian grippers for loading, unloading, and the sorting of parts. Each gripper is capable of using vacuum or magnetic tools in a variety of shapes and sizes to produce a more effective sorting speed. The process sorts the parts into kits, and its wide variety of options allows for different material thicknesses to be kitted on the same pallet. Downstream processes are taken into account to provide seamless integration into the production process.

Introducing The LASERDYNE® 890 Fiber Laser System Early users asked for it, Prima Power Laserdyne made it happen, the renewal of the 890 LASERDYNE® Multi-Axis Laser Processing System. This is an all-new LASERDYNE 890 system with powerful and efficient fiber laser, the latest highly flexible BeamDirector®, and the S94P control loaded with a full portfolio of Smart Techniques™ operating capabilities. With all of these enhancements and a large 96 x 72 x 36 inch work envelope for the X, Y, and Z axes -- along with the latest BeamDirector and a complete flexible five axis work envelope -- the modern LASERDYNE 890 is designed for today’s challenging large part welding, drilling and cutting processes.

» For more information, visit www.mcmachinery.com

» For more information, visit www.primapowerlaserdyne.com

New Norton Rapid Prep™ XHD Abrasive Discs Offer Single Step Weld Blending & Grinding Saint-Gobain Abrasives offers new Norton Rapid Prep™ XHD Coarse and Medium Discs to solve users’ most aggressive stock removal and blending challenges. The extra heavy-duty non-woven discs remove weld lines, weld splatter, weld discoloration and blend surfaces in a single step. XHD Coarse is ideal for surface blending on steels, while XHD Medium works well on softer metals/alloys. The new Norton Rapid Prep XHD discs offer a unique combination of a conformable fiber matrix and premium ceramic grain, resulting in improved cut control and surface blending over traditional coated flap and fiber discs. » For more information, visit www.nortonabrasives.com

Radian Laser Systems Announces New Industrial Grade, Made in the USA, CO2 Galva Laser Modular Marking System Radian Laser Systems has designed and manufactured the fastest and smallest modular marking system on the market today. This new system revolutionizes industrial automation, as it allows marking technology to be easily integrated into larger production infrastructures without the need for a new large piece of equipment.

The heart of Radian’s new Modular System is the Dynamic Focus Module in combination with Radian’s proprietary API driven controller, which allows for 3D marking on curved surfaces without rotation of the work piece. This technology is easier to operate and improves productivity. » For more information, visit www.radianlaser.com

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44 IMD DECEMBER 2019

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IMD 47

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Ad INdex Actek Manufacturing and Engineering Inc. — www.actekmfg.com ............................................ 33 ADB Hoist Rings Mfg. — www.adbhoistrings.com ........................................................................... 25 Air-Vac Systems — www.air-vacsystems.com ..................................................................................39 Amada Marvel, Inc. — www.marvelsaws.com .................................................................................... 5 AmCon Design & Contract Manufacturing Expo — www.amconshows.com ..........................46 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ......................................... 15 Attica Hydraulic Exchange — www.ahx1.com .................................................................................. 23

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MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ...........................42 Messer Cutting Systems, Inc. — www.messer-cs.com ..................................................................... 9 Performance Racing — www.performanceracing.com ............................................................... IBC Pro-Line — www.1proline.com ............................................................................................................49 Quality Vision International — www.certifiedcomparator.com ....................................................49 Radwell International, Inc. — www.Radwell.com .......................................................................... IFC RAS Machine Tool Technologies Inc. — www.rasmachinetool.com ...........................................43 Royal Products — www.mistcollectors.com .....................................................................................49 Scotchman Industries, Inc. — www.scotchman.com ..................................................................... 27 Select Equipment Company — www.selectequipment.net ..........................................................48 South Bend Lathe — www.southbendlathe.com ............................................................................... 3 Standard Direct.com — www.Standard-Direct.com ....................................................................... 47 Stor-Loc — www.storloc.com ............................................................................................................ BC Suhner Industrial Products — www.suhner.com ..............................................................................17 The Electric Barn, Inc. — www.electricbarn.com ............................................................................ 47 The Grieve Corporation — www.grievecorp.com ......................................................................... 7, 8 Tormach — www.tormach.com .......................................................................................................... 18 Trim-Lok — www.trimlok.com .......................................................................................................35, 37 US Shop Tools — www.usshoptools.com ..........................................................................................11

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DECEMBER 2019 IMDdirectory-Listed-TV-01-2019.indd 1

3/26/19 8:59 AM

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