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Manufacturing Showcase: Houston Plating & Coatings IndustrialMachineryDigest.com
December 2021
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Table of Contents
COLUMNS
10 12
BUSINESS 4.0 Recovery Continues Across the Manufacturing Sector
TALKING SHOP REVIEW
20 FEATURES
18 20 24
Houston Plating & Coatings
WORKFORCE DEVELOPMENT
Cobots in Classrooms
14
NEW TECH Discovering New Opportunities Mazak’s DISCOVER 2021 Event Premieres New Technologies, Facility Expansions
14
MANUFACTURING SHOWCASE
28 PROCESS
44
SAFETY & MAINTENANCE Human-Centered Design Drives Latest Generation of HighPerformance HMIs
SURPLUS BUYING AND SELLING Stop Industrial Circuit Board Corrosion By: Del Williams
The Great 8 of Manufacturing and Why You Need Them By: Mike Melzer, VP of Operations & Service Global Shop Solutions
34
INDUSTRY INSIGHTS
DEPARTMENTS
Quick and Easy Simulation of Drives
6 EDITORIAL DIRECTIONS 8 INDUSTRY NEWS 40 PRODUCT SHOWCASE 49 CLASSIFIEDS 50 ADVERTISER INDEX
ON THE COVER
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4 IMD DECEMBER 2021
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Editorial Directions December is often a month of reflection. With the new year ahead of us, it only makes sense to look back at the year that we have had. For most, 2021 has been a continuous year of recovery. While the impacts of the pandemic are far from behind us, the manufacturing industry has taken great strides to overcome the challenges that COVID-19 created. This should be of little surprise, especially for our readers. The industry was already poised to adopt advanced automation solutions, many of which had been created in response to the skills gap that existed well before the pandemic. We also saw a return to in-person events, such as Northwest Machine Tool Expo, Motion + Power Technology Expo, and FABTECH. These events allowed our team to connect with colleagues, some of which we hadn’t seen in almost two years, and to check the pulse of the industry. While most are sharing the brunt of logistic headaches, in terms of sourcing materials, and even shipping product, the general response has been overwhelmingly positive. 2022 is poised to be a pivotal year. This is true for Industrial Machinery Digest as well. Next month, we will debut the redesigned monthly print edition of IMD. While you will still be able to discover the latest in equipment, technology, and services available, you will also notice a few changes that make it easier to connect and engage with the content in each issue. We are excited to be able to deliver even more solutions geared towards manufacturing professionals, big or small, every month. Before we get too far ahead of ourselves, I think it is important for us to take a moment to recognize how far the industry has come thus far. While the pandemic has touched each of our lives, some more than others, manufacturers and fabricators across the country have proven their resilience in the face of unprecedented challenges. As always, Industrial Machinery Digest is proud to be North America’s manufacturing resource for industry professionals.
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6 IMD DECEMBER 2021
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Industry News Siemens Named a “Leader” in Industrial Internet-ofThings Software Platforms Q3 2021 Report Siemens Digital Industries Software announced today that it has been named a “leader” in The Forrester Wave™: Industrial Internet-of-Things Software Platforms, Q3 2021 report. The report researches, analyzes and scores eight vendors against written and quantitative multi-dimensional criteria for Industrial IoT platforms, measuring current offering, strategy, and market presence. Forrester named Siemens as a “Leader”. According to the report, “MindSphere offers a comprehensive array of capabilities to simplify routine monitoring, management, and interaction with connected devices, even at scale. MindSphere is delivered, as a service, from Amazon Web Services (AWS), Azure, and (in China) Alibaba and can also be installed in other environments. Developer support and training are comprehensive and localized, and the vendor offers them in 13 languages.” Siemens received the highest possible scores in the support for digital industrial platform, execution roadmap and average deal size criteria and the highest score in the market presence category.
Tormach Outlines Its Machine Tool Right To Repair Policy
service their own equipment, but that we encourage and support this, at no cost to the user beyond replacement parts.” One example of Tormach’s customer repair policy is, if a Tormach CNC machine requires a spindle replacement, users can buy the spindle directly from the website and replace it themselves, with technical support and documentation readily available from Tormach at no cost. Other machine tool companies not only charge for the part, but also require it be installed by a factory-authorized service person. This service fee typically costs thousands of dollars and in some cases, takes multiple weeks of downtime to schedule the service call. With the ability to repair one’s own machine, users not only save on cost, but can gain flexibility and autonomy in the process.
Mazak’s New MPower On-Demand Learning System Makes Training More Accessible to Manufacturers As one of the key components within Mazak’s MPower customer support program, the company’s new online MPower On-Demand Learning (MODL) system further enhances training and makes essential courses easily accessible to today’s busy shops. Customers value the ability to improve productivity with in-depth knowledge of all aspects of their Mazak machine tools, but not all shop personnel can travel to in-person classes, and many shops are unable to afford the disruption of production shifts while operators attend off-site training sessions. MPower On-Demand Learning offers online instruction and virtual experiences that provide all the engagement of in-person instruction with the same standards of results. It also enables Mazak to customize its course offerings, and subject matter, to meet customer requests and adapt classes to suit learning levels. This ensures that shops always have access to exactly the right classes that will empower their teams to learn more and do more.
Global Shop Solutions Names John Davis Chief Technology Officer A recently released video on YouTube from Tormach, Inc. has generated a lot of industry buzz concerning the hot topic of ‘Right to Repair’. Tormach’s CEO, Daniel Rogge, talks about the company’s long-time philosophy of allowing customers to service their own Tormach machinery and equipment. “Clearly this video has touched a nerve not only in the machine tool industry, but in the overall right to repair movement,” said Rogge. “We thought it was important to communicate that it is, and has always been, Tormach’s policy to not only allow owners to
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8 IMD DECEMBER 2021
Davis joined Global Shop Solutions in 2004, and over the past 17 years has served the company in many different capacities including analyst, programmer, and management. Most recently he led the R&D Infrastructure Team, and his excellent programming, networking, and all-around technical knowledge has played a critical role in shaping the company’s ERP software product. “John has been instrumental in leading Global Shop Solutions technical strategy so our customers can take advantage of the benefits IoT brings to the manufacturing industry,” says Erika Klein, VP of R&D. “As CTO he will define the standards for the technical excellence we hold ourselves to.” An experienced systems analyst in the computer software industry, Davis combines strong Visual Basic, Object Oriented Design, SQL, Perl, and C++ skills with a background in Computer Resource and Instructional Planning. He received his degree in Interdisciplinary
IMD – The Industry’s Most Extensive Industrial Publication
Studies with an emphasis in Computer Science, Business Information Systems, and Instructional Technology from Utah State University.
Acme Alliance Wins 2021 National Metalworking Reshoring Award
EZ-PULLER
The 2021 award was presented on the FABTECH Main Stage at McCormick Place in Chicago by Harry Moser, Founder and President of the Reshoring Initiative. The award honors companies that have effectively reshored products, parts, or tooling made primarily by metal forming, fabricating, casting, or machining, including additive manufacturing. The award is made possible by the Reshoring Initiative, the Precision Metalforming Association (PMA), The Association For Manufacturing Technology (AMT), and the National Tooling and Machining Association (NTMA). SME generously provided the venue and audiovisual recording. Mauri Mendes, President of Acme Alliance-Lovejoy Industries, said, “In our business model, we use our worldwide manufacturing footprint to produce and deliver products to the regions where they are assembled [and used] by our customers. We truly believe being close to our customers is the most important strategy. We are seeing
many large organizations switching their strategy by reshoring their supply chain.” Matt Thavis, Director of Business Development, and JR Kinnett, General Manager, provided additional insight into Acme’s success. Acme Alliance was chosen for several reasons, according to Moser. “Acme has a record of reshoring products for their customers. In one case, their reshoring fixed a quality problem and cut the customer’s inventory by 94 percent. Acme also has successful facilities in Brazil and China. By not shipping from those facilities to the U.S., Acme has proven that reshoring is not only possible but the right business choice.”
Demand for New Vacuum Furnaces Continues at Ipsen New equipment orders since the beginning of July have come from customers in ten states across the U.S., as well as four other countries—India, Japan, Mexico and Taiwan. Customers will be using the furnaces for processing a range of products including heat exchangers, jet engine components, fasteners and saw blades. Aerospace customers accounted for the majority of sales, but Ipsen also reports an increase in orders from emerging industries focused on electric vehicle production and additive manufacturing. Many of these are long-standing customers who continue to purchase Ipsen equipment for the reliable service, quality products and technical expertise. Other customers cite process flexibility, turnkey solutions and adherence to industry standards as reasons for purchasing from Ipsen for the first time.
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IMD 9
Business 4.0
Recovery Continues Across the Manufacturing Sector September 2021 Manufacturing Technology Orders Total $590 Million
O
rders of new manufacturing technology totaled $590 million in September 2021, according to the latest U.S. Manufacturing Technology Orders Report published by AMT – The Association for Manufacturing Technology. This was a 9 percent increase over August 2021 orders and nearly a 60 percent increase over September 2020. Year-to-date orders in 2021 totaled $4.115 billion, a 53 percent increase over the total through the first nine months of 2020. “It took 31 months after the bottom of the 2008-2009 financial crisis to have a single month with half a billion dollars in orders, but September is the third month of 2021 exceeding that mark,” said Douglas K. Woods, president of AMT. “Economists project the United States is past peak growth, yet machine orders remain at a record pace to meet remaining consumer and producer demands.” “Machine shop orders usually dictate the direction of the month,” said Woods. “September 2021 was an exception to that trend, which highlights the breadth of the recovery across manufacturing sectors.” After machine shops, the engine, turbine, and power generation sectors had the largest share of orders in September 2021 and their highest monthly value since December 2011. Research indicates these outsized investments are the result of efforts to increase power grid resilience after a year that saw extreme weather test its durability. The United States Manufacturing Technology Orders (USMTO) Report is based on the totals of actual data reported by companies participating in the USMTO program. This report, compiled by AMT – The Association for Manufacturing Technology, provides regional and national U.S. orders data of domestic and imported machine tools and related equipment. Analysis of manufacturing technology orders provides a reliable leading economic indicator as manufacturing industries invest in capital metalworking equipment to increase capacity and improve productivity.
voice to speed the pace of innovation, increase global competitiveness, and develop manufacturing’s advanced workforce of tomorrow. With extensive expertise in industry data and intelligence, as well as a full complement of international business operations, AMT offers its members an unparalleled level of support. AMT also produces IMTS – The International Manufacturing Technology Show, the premier manufacturing technology event in North America. For more information, visit www.AMTonline.org
ABOUT IMTS INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW The largest and longest running manufacturing technology trade show in the United States is held every other year at McCormick Place in Chicago, Ill. IMTS 2022 will run Sept. 12-17. IMTS is ranked among the largest trade shows in the world. Recognized as one of the world’s preeminent stages for introducing and selling manufacturing equipment
ABOUT AMT
and technology as well as connecting the industry’s supply chain. IMTS
THE ASSOCIATION FOR MANUFACTURING
attracts visitors from every level of industry and more than 117 countries. IMTS 2018 was the largest in number of registrations (129,415), net
AMT – The Association for Manufacturing Technology represents
square feet of exhibit space (1,424,232 sq. ft.), booths (2,123) and
U.S.-based providers of manufacturing technology – the advanced
exhibiting companies (2,563). IMTS is owned and managed by AMT –
machinery, devices, and digital equipment that U.S. manufacturing
The Association For Manufacturing Technology.
relies on to be productive, innovative, and competitive. Located in McLean, Virginia, near the nation’s capital, AMT acts as the industry’s
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For more information, visit www.IMTS.com
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Talking Shop - Review
TALKINGSHOP IMD TALKING SHOP YEAR IN REVIEW
Cracking the Code: Connecting IMD Readers with More Information This year, Industrial Machinery Digest, “talked shop” with ten leaders in the manufacturing industry. To read the full interview, scan the included Quick Response (QR) code with your mobile device. These special barcodes have been designed to allow our readers to quickly and easily discover more information available on IndustrialMachineryDigest.com
Chris Pollack – Manager Virtual Technical Application Center, Siemens
Cate K. Smith, J.D., M.P.A. – Executive Director Precision Machined Products Association (PMPA)
What kind of support do you provide end-users moving forward as they encounter challenges and as your technologies evolve?
How has the PMPA helped its members weather the recession and pandemic, and how will you continue doing so once recovery begins?
In terms of staying in touch with our customers, we are constantly sending them information about available upgrades, upcoming seminars, and any Siemens event from which they might benefit. We have an incredible wealth of resources to offer…
As a case in point, we knew our members were essential industries even before the government did, because we started receiving RGQs for large numbers of ventilator parts requiring fast-track delivery times. We knew that our members…
Douglas K. Woods – President The Association for Manufacturing Technology (AMT)
Mike Gamache – Business Development Manager Gamache Systems, a Division of Metalcraft of Mayville
Once we recover from the twin fists of a pandemic and an economic recession, do you believe we will have learned any valuable lessons?
Apart from design, what other benefits does a systems integrator provide?
I think it’s clear that we’ve learned a lot in terms of streamlining and rethinking how we go about doing business. For instance, augmented reality is now a mainstay in how we talk about machine tools and peripheral devices, while at the same…
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One of the biggest challenges manufacturers are facing right now is how hard it is to find machine operators and skilled labor. And when you can, you don’t want to waste their time on dull, monotonous tasks. That’s when a robot is particularly effective at addressing unattended machine time…
IMD – The Industry’s Most Extensive Industrial Publication
American Gear Manufacturers Association Matthew E. Croson – President American Gear Manufacturers Association
Ryan Hiss – Vice President of Sales Better Engineering
Despite all the hardship, what are your thoughts on how we’ve weathered this storm as a country and an industry? Have we learned any important lessons?
I know that you specialize in aqueous processes that use eco-friendly detergents. Could you expand on these technologies and their applications?
I am so proud of how we’ve come together as a country, just our ability to pivot from normalcy to radical change. It’s been truly inspirational, and I commend all these leaders – especially in the manufacturing industry – on their optimism…
The first method is spray washing, which is just like being in a shower. This is useful for flat surfaces like sheet metal and parts with fairly simple geometries. Then you have immersion washing, which is a bath. This is better for more complex parts that have…
Paul Aiello – Director of Education FANUC America
Robert W. Roth – President American Welding Society
Has the COVID pandemic altered your approach to thinking about workforce issues, or reaching out to students and educational systems in any way?
What would you say to someone considering pursuing a career in welding?
It definitely has. For instance, within industry, you can see three sectors in particular – food production, supply chain, and medical equipment – that had become vulnerable because they were located so far outside the United States…
I would encourage that person to be aware of the many different positions required to fill out the infrastructure of this industry. You don’t necessarily have to be a welder to participate in that. There are roles to be played in engineering, web development, print publishing, and hundreds of other supporting fields. And no matter…
Matt Sand – President 3DEO
Eric Goodwin – President Goodwin Recruiting
Do you find that first-time customers return with fresh ideas about how they can further utilize 3D Printing?
What is the most basic advice you give your own clients?
That happens frequently. Once a customer has seen the quality of the parts, the ease of making design improvements, lower costs and shorter lead times, they start looking around at other ways they can harness additive manufacturing to their benefit. It’s not uncommon to see increases of as much as 10 times; from…
We want our clients to truly understand that everything has changed post-pandemic. People are weighing issues like quality of life rather than income alone. You’ve probably read about folks who took the time in quarantine to evaluate their lives and maybe choose a different direction. It’s not just a matter… INDUSTRIAL MACHINERY DIGEST.COM
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IMD 13
Safety & Maintenance
Human-Centered Design Drives Latest Generation of High-Performance HMIs Focus on the operator creates more intuitive and effective process control and management for increased efficiency and safety
F
or decades, operators in manufacturing facilities have relied on Human Machine Interfaces (HMI) for a visual overview of their process systems to monitor critical status and control information. A properly designed graphical user interface improves situational awareness, reduces workload, and enables the operator to view the entire process at-a-glance so they can focus on mitigating abnormal situations. At stake is more than just operations efficiency, but also product quality, manufacturing throughput, operations profitability and foremost, overall safety. Poor HMI designs have been identified as factors contributing to abnormal situations, lost production and even accidents. In response, today’s more advanced HMIs are designed to help people optimize operational performance, improve situational awareness, and recognize issues before alarms occur. These high-performance HMIs are helping operators make better, faster, and more informed decisions. “Issues with HMI design began when we first moved from physical switches and controls to a keyboard and mouse. The industry got excited that suddenly we could show a lot more information than we were able to before because everything was now digital,” said Michael Simmers, Lead Field Engineer at NovaTech Automation, a Pennsylvania-based provider of process control and optimization solutions, including the TotalVision graphics engine/HMI. “As a result, a lot of data landed on an operator’s screen just because it was possible. But too much information makes it hard for an operator to focus on the right information in real-time.” The user interface issues with early HMIs persisted for many years. Operators had to work with very dense displays and were often limited to a single monitor. Process drawing displays of the physical layout of a plant were difficult to read, and graphic user interfaces (GUI) typically used bright lines, text, and a myriad of bright colors on dark backgrounds that caused viewing fatigue.
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Pictures, motion, and items such as dynamic flames, rotating agitators and twisting screws were even incorporated into backgrounds. But while these graphical capabilities are great for showcasing and selling graphics packages, they offer very little benefit to controlling a plant from a human factor and operator usability standpoint. Over-alarming and the lack of a big-picture view further impeded the work of operators causing them to respond to alarms without understanding the root cause of the alarm conditions. “Plants don’t want to be blindly run by alarms,” said Simmers. “What you need most from your HMI is overall situational awareness to mitigate abnormal situations and to have context when an alarm does occur. Maintaining situational awareness requires a process of deprioritizing all non-critical information. Then we ensure the key information is where an operator can easily see it so they can act upon it.” He added, “Consider that an operator may be working for 12 hours at a time. The better you can present the information, the easier it is for that operator to focus on their work and prevent safety issues from occurring.”
Human Centered Design HMIs have made significant advancements in usability based on an improved understanding of how people actually use and process information. For example, high-performance HMIs now use muted backgrounds with normal or non-critical data presented in varying shades of gray (or other neutral colors) for ease of viewing over extended periods. Alarms stand out in color in contrast to the muted background with bright saturated color reserved only for abnormal situations. Displaying historical trend data has also required a more user-centric design focus. To show something like a percent level in a tank, early HMIs relied on text and numbers that would fluctuate over time. Today, high-performance HMIs can embed graphical trends so operators can identify how the current value compares to relevant past time intervals (hours, minutes), providing valuable context. Even the presentation of the information and speed of comprehension is considered in high-performance HMI layouts. For example, a simple list of numbers or results does not provide enough context for an operator to use. Showing numbers inside an expected range helps, but this still requires an operator to take time
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to understand and evaluate the information. Sliders bars are useful for displaying values within the context of their normal operating ranges. But ideally, the graphic shows all the above: trend, slider bar and alarm indication. “Trend data is not new,” said Mike Davis, Director of Process Offering at NovaTech Automation. “What is different now is that rather than having to navigate to a separate screen to view a trend, the information is on the main screen next to the associated process variable enabling the operator to analyze data much easier, always depicting where they are and how they are doing versus target performance levels.”
Configurable High-Performance Graphics NovaTech’s TotalVision® HMI integrates with their D/3® distribution control system (DCS) - an open connectivity platform which controls key variables such as flow, applied temperatures, pressure, level and material conveying/handling for managing batch, continuous and hybrid processes.
Based on the interface to the D/3 system, TotalVision can also connect to OSIsoft PI and other data sources to provide process and analytical information to operations and management. Historical and live data are presented graphically to support real-time decision making. TotalVision supports multiple windows and monitors in almost any configuration, making it easy to set up a hierarchy of displays so that operators always have a complete view and control of the process. The company uses Sequence and Batch Language (SABL®) to allow operators to interact with control applications through the HMI. “SABL is a strong key to our platform,” said Simmers. “We chose SABL because it is a flexible platform that is built around ISAS88 batch management and ISAS106 procedural automation standards. Because all of our software developers program in SABL, anyone on the team can help a client customize their HMI.” Engineers typically work with clients to identify the setpoints and measurements that are needed on the main screen. NovaTech provides a library of pre-made dynamic objects that is part of the standard product and helps customers to build high-performance graphics for an operator to control a process, enter information, and interact with sequence programs. A client has multiple ways to customize their HMI, including selecting the choice of colors. “It’s an entire system for the HMI to display information from our D/3 control system,” said Davis. “It’s about more than just graphics; we work with the client to optimize the interaction between the operator and the control system. Each plant has different needs, so we customize accordingly.”
HMI Integration with DCS The advanced capabilities of today’s HMIs enable managers and supervisors to do much more than control processes. Real-time process intelligence offers vast new opportunities to improve product quality and make systems more efficient. One of the high-performance features NovaTech introduced is a standard configurable header area that displays everything that the D/3 DCS program does via text and messaging at the top of the main screen. “With the DCS controlling the process, the header in the HMI is telling the operator the story as it is happening,” said Simmers. “Should something fail or be interrupted, the operator has all the information needed at the top of the graphic. Perhaps a certain valve failed to open or close, a process went to hold as a result, and there is a failure notification. But instead of just acknowledging the alarm, the operator can immediately see what went wrong and why.” “It’s all about making it easy for the operator to control the plant,” said Simmers. “With a customized information-driven interface that is thoughtfully designed around the needs of the operator, high-performance HMIs are bringing a new level of process control and management to manufacturing.” For more information about NovaTech Automation and their family of process automation solutions, visit www.novatechautomation.com or call (844) 668-8324.
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IMD 17
Manufacturing Showcase
Houston Plating & Coatings H ouston Plating & Coatings was founded in 1988 in South Houston, Texas to provide electroless nickel plating services to energy equipment manufacturers. In subsequent years additional corrosion and wear protection finishing service lines (phosphate, a wide variety of corrosion protection spray coatings and salt bath nitriding) were added to satisfy the majority of product finishing requirements of energy equipment OEMs. The company added a second plant in Humble, Texas in 2008, and now has 155 employees. Current executives include William Howard, CEO; Eric Turner, COO; Albert Landois, Vice President of Production; and Tim Foster, Head of Maintenance. The company seeks to employ supply chain principles for the majority of its customers, which include companies from industries as diverse as firearms manufacturers and power generation manufacturers in addition to oil field equipment OEM’s, to differentiate itself from the typical job shop operation.
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HP&C has been named one of the top 50 companies for both plating and coating in North America for 4 years, and in 2020 was named the overall best coating company. HP&C positions itself as a ‘one-stop-shop’ for customers’ corrosion and wear protection needs offering an exceptionally broad range of plating and coating services with Ni-side TM a new, patent pending process for nickel plating high pressure gas cylinders. HP&C is new to the Industrial Gas Industry so the revenue at this point is negligible. However, discussions with industry executives lead the company to conclude that there is a significant volume of cylinders that need to be plated annually, so HP&C are expecting it to become a significant part of their revenue stream in the coming years. In previous years, the availability of plated cylinders has been limited, but HP&C’s processes dramatically improved that, so they are expecting that the overall use of plated cylinders will increase
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once it becomes known that now there are plenty of nickel plated cylinders available. In addition to plating the cylinders, HP&C understands that many other vessels used for storage, some many times the size of high-pressure cylinders, would benefit from nickel plating. Interestingly, their first job for the Industrial Gas Industry was not to plate a high-pressure cylinder, but to plate several large storage tanks. The Ni-side process, while developed for plating high-pressure cylinders, could theoretically be used to plate virtually any size vessel used in the industry. HP&C strives to take the “friction” (delays) out of the finishing process through supply chain based customer service tailored to specific customer needs, and an unmatched commitment to quality. “The new cylinder plating business is a good example of that philosophy,” says William Howard, CEO of HP&C. “HP&C is talking with several customers about what we call ‘drop-shipping’ where a company purchases cylinders from an OEM, who ships them directly to HP&C for plating rather than to the purchaser. Once they have been plated, we then ship the plated cylinders to the purchaser which eliminates transportation costs and speeds up the overall process. We have also discussed a program to store a large quantity of cylinders for a customer and supply the company with just the number of plated cylinders that are needed each month.” HP&C is in discussions with an OEM and their customers about potential supply chain principles that will speed up the process and cut overall costs, but some of those issues will become evident as they become more familiar with industry practices. A key advantage is that HP&C has some of the largest EN tanks in the industry and can dedicate a full production line to the new cylinder plating processes; and, since the company’s new EN plating processes can plate many cylinders at one time, they can deliver a large quantity of plated cylinders at a significantly lower cost. “From discussions we have had with industry executives, we understand that historically, using standard plating processes resulted in the number of cylinders that could be plated in a day was limited to only about five or six,” explained Howard. “Plating high-pressure gas cylinders is difficult because the very narrow opening into the cylinder as well as its configuration inhibits necessary solution flow. The processes and fixtures that we have developed can plate up to 72 cylinders in a standard day, however, the process is very scalable. It could be expanded exponentially, and theoretically, we could supply a virtually unlimited number of plated cylinders to the industry.”
team devised new fixtures and procedures and achieved a 100 percent plating accuracy.
Other Advantages to EN EN can also be used to repair mis-machined or damaged parts that would otherwise be scrapped. HP&C’s electroless nickel deposition process can often rescue these parts through rebuilding internal or outside diameters to the required tolerances with additional nickel plating. Extra nickel may correct a part that was mis-machined and slightly out of tolerance, saving the part.
Key Message to Industrial Gas Producers and Distributors “HP&C has been successfully plating energy equipment and other manufactured parts for every major energy OEM, including Baker Oil Tools, Schulmberger, Halliburton, SPX, and Cameron, for over 30 years,” said Howard. “We have no reservations about our ability to deliver not only the highest quality but a significantly increased volume of plated cylinders to the industrial gas industry, and we look forward to becoming a valued and trusted member of the industrial gas industry supply chain.” For more information, visit www.houstonplating.com
HP&C Has Several Competitive Advantages There are many companies that offer nickel plating, both electroplating and electroless plating, in the country, but typically their tanks are relatively small, which limits the volume and the size of the parts that can be plated. However, with some of the largest tanks in the country and over 30 years of plating experience, HP&C offers unique advantages for many of its customers. For instance, a power generation company in Pennsylvania was experiencing over 70 percent failure rate of its plated parts which are indeed difficult to plate due to a number of issues. The HP&C plating INDUSTRIAL MACHINERY DIGEST.COM
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Workforce Development
Cobots in Classrooms
Two major recognitions of Universal Robots’ education programs from the U.S. federal Advanced Robotics for Manufacturing Institute (ARM) and the State of Ohio’s Department of Education pave the way for schools and industry to further leverage cobots, offering employability in robotics careers while upskilling existing workforce.
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hen schools educate students in mastering new technology, they look to validate that the hardware and software they use in the curriculum is relevant to companies employing graduates. Educational institutions also need to ensure that funding for acquiring the classroom technology is obtainable. Two recent endorsements of Universal Robots’ (UR) products and educational curriculum awarded by ARM and the Ohio Department of Education offer schools that insight, emphasizing the importance of UR’s collaborative robots (or ‘cobots’) in today’s manufacturing processes and in classrooms; UR is the first robotics manufacturer to
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be selected for ARM’s new Endorsement Program as ARM reviewed UR’s Educational Robotics Training program. At the state level, Ohio becomes the first U.S. state to evaluate and add UR courses to its Industry-Recognized Credential List (where it sits at 6 credit points for the 2021-2022 school year and onwards). “These endorsements mean the world to schools hoping to introduce hands-on cobot courses in their classrooms,” says Channel Development Manager at Universal Robots, Corey Adams. “The educational legitimacy of UR cobots opens the door to applying for both expanded federal funding and in Ohio also state funding to acquire cobots. And it gives schools
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confidence that they are not only offering students a diploma but also an instant career path.”
Support From Major Industries In order to make the Ohio Department of Education’s credentialed list, numerous companies in the state, including major Tier 1 automotive makers and home appliance manufacturers, vouched for the UR cobots, detailing how they use them on the shop floor and need an ever-expanding, educated workforce to deploy, program and operate them. “Ohio is industry leading in recognizing manufacturing technology and we expect this to quickly cascade out to other states as well,” says Adams who is actively working with numerous states in obtaining educational credentials. The Department of Defense-sponsored ARM Institute is a 300+ member organization that catalyzes robotic technologies and education solutions to strengthen the U.S. industrial base and secure U.S. manufacturing resiliency. ARM launched the Endorsement Program earlier this year in conjunction with RoboticsCareer.org, the ARM Institute’s national workforce capability that connects education seekers with training for manufacturing careers.
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ARM Conducted Rigorous Audit Brian Wilson chairs the Education and Workforce Advisory Committee at ARM and audited the UR Robotics Training Program: “It’s a very rigorous audit that made it apparent that UR listened and adapted to industry needs,” he says. “There is a big push for cobots that are affordable, that can easily be redeployed in different applications, and that are for both the large enterprise but also for the entrepreneur. Our endorsement is not just an academic accreditation; we look at whether the program helps the industry educate the workforce they need right now.” In the evaluation of the UR program, ARM stressed the ‘training of the trainer’ aspect that ensures the quality of the teaching. “It’s also a course that can be offered from high school to industry professionals,” says Wilson. “There are many on and off-ramps in the lifelong learning journey and UR figured out how to make people embark on that journey at different career stages.”
Ripple Effect Through Supply Chains At the Columbus State Community College in Ohio, the director of the Manufacturing Extension Partnership (MEP), Jeff Spain,
ABOUT UNIVERSAL ROBOTS EDUCATIONAL ROBOTICS TRAINING PROGRAM The curriculum was created to provide a student-focused, hands-on instruction with a blended (in-class and hands-on) delivery that includes student-based projects, expanded training on interconnectivity and a clearly defined pathway for students to pursue an Advanced Manufacturing / Robotics Industry 4.0 career. The program integrates Employability skills, Project Management, Problem Solving, and Critical Thinking skills with the UR Robotics I4.0 Environment. The program aligns with ARM Model, RIA Compliancy, and National Credentialing.
ABOUT UNIVERSAL ROBOTS explains how the college is now building a mixed lab space for cobots, that will focus on both professional development for manufacturing employees while also educating the next workforce generation to hit the ground running with cobots. “With their reduced footprint and intuitive programming, cobots have been a major disruption to industrial automation and are within that Industry 4.0 sweet spot of technology solutions that we find that our local employers need funded education programs for,” he says. “When large companies endorse UR cobots, it has a ripple effect through the supply-chains as Tier 1-3 suppliers and other industries realize that here is a vetted, nimble technology, that we have found offers low risk.”
Universal Robots aims to empower change in the way work is done using its leading-edge robotics platform. Since introducing the world’s first commercially viable collaborative robot (cobot) in 2008, UR has developed a product portfolio including the UR3e, UR5e, UR10e, and UR16e, reflecting a range of reaches and payloads. Each model is supported by a wide range of end-effectors, software, accessories and application kits in the UR+ ecosystem. This allows the cobots to be used across a wide range of industries and means that they can be flexibly redeployed across diverse tasks. The company, which is part of Teradyne Inc., is headquartered in Odense, Denmark and has offices in the USA, Germany, France, Spain, Italy, the Czech Republic, Romania, Russia, Turkey, China, India, Japan, South Korea and Mexico. Universal Robots has installed over 50,000 cobots worldwide.
Learn more: www.universal-robots.com
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New Technology
Discovering New Opportunities
Mazak’s DISCOVER 2021 Event Premieres New Technologies, Facility Expansions
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ore than 1,500 attendees from across North America attended Mazak Corporation's DISCOVER 2021 event, as the company premiered its new SYNCREX Series of Swiss-style machines and presented its latest campus expansion to support these new machine tools. The event, held at Mazak's North American Headquarters in Florence, Kentucky, from October 25-29, featured a wide variety of technologies, insights from leading
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industry experts and tours of the company's facilities, including 32,000 sq. ft. of new production and aftermarket parts warehousing to accommodate Kentucky production of the new SYNCREX Series. In addition to the introduction of the new SYNCREX Swissstyle series of machines, attendees also saw numerous North American machine premieres at DISCOVER. The Kentucky campus will accommodate manufacturing and parts supply for SYNCREX,
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designed for high-volume production of small, precise parts. Among the 25 machines under power at DISCOVER, other debuts included the first in-person North American showing of the compact Mazak Ez Series. Designed to support job shops, the Ez series offers Mazak quality and performance at an affordable pricepoint. Additionally, the company debuted its INTEGREX i-H Series of Multi-Tasking machines with the new MAZATROL SmoothAi CNC, which uses artificial intelligence and machine learning to improve efficiency and precision. High attendance and new-customer interest in Mazak technologies attest to the strong momentum in the manufacturing industry, with more than 25 percent of DISCOVER 2021 attendees being new to Mazak. Customers crowded around the Mazak Ez Series and SYNCREX Swiss-type machines at the event, attracted to the barrier-dropping price of the Ez Series and the addition of Swissstyle machining to the Mazak lineup. "We knew that these machines filled important needs for job shops and manufacturers in industries from high tech to transportation,” said Dan Janka, president of Mazak Corporation. "We continue to expand our product lines and our production capacities to meet the surge in demand that's giving manufacturers new competitive opportunities." A long list of focused demonstrations and walk-up presentations rounded out DISCOVER 2021 with technology previews geared to workflow productivity on the shop floor. There was special focus on MPower, Mazak’s new Complete Customer Care program, which provides single-source end-to-end support throughout the life of every Mazak machine tool. To assist with the machine acquisition process, DISCOVER also spotlighted Mazak Capital Equipment Financing (MCEF), which is the company’s one-stop solution for shops to purchase or lease their machine tools directly through Mazak itself. "We dedicated this event to 'Move Manufacturing Forward,' and made it a showcase of technology and ideas that our customers can use to propel their success. Our theme reflects the ways we always want to help our customers advance," said Dan Janka. Tours of the Mazak iSMART Factory™, the company's fully automated and networked production facility, gave attendees a close look at how the company uses its machines to produce its
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machines. As a showcase of Mazak Digital Solutions, the factory exemplifies the value of digitalized production to provide in-depth insights that manufacturers can use to resolve manufacturing bottlenecks and improve productivity. Attendees also visited the Mazak ISO 9001:2015 Spindle Rebuild Center, which guarantees the highest precision and quality in spindle service. Beyond the over 1,500 in attendance, virtual visitors took advantage of DISCOVER ON-DEMAND to view presentations and demonstrations through a mobile app or web browser.
New Swiss-Style Machine Series Mazak further expanded its machine tool technology portfolio with the debut of Tours of the Mazak iSMART Factory™, the company's fully an all-new line of SYNCREX automated and networked production facility, gave attendees a close look at how the company uses its machines to produce its Swiss-style machines at the machines. Photo by: Nick Boliek company’s DISCOVER 2021 event. With Mazak’s well-known performance and quality, the extremely precise SYNCREX models feature seven, eight and nine-axis configurations and are optimized for high-production of small parts. These new Swiss-type machines use a collet plus single-motor ball spline drive for heightened accuracy and reduced material waste. A 10,000 rpm spindle and a variable vibrating system ensure the utmost in stable, repeatable performance. "Now shops can count on Mazak quality to expand their productivity into new areas and applications," said Dan Janka, president of Mazak Corporation. "We are excited to showcase this new technology at DISCOVER 2021 and give our customers new reasons to choose Mazak. We are also extremely proud to produce the new series in Kentucky and are in the process of adding a new building to our Florence campus specifically for that production." Mazak's SYNCREX machines accommodate a maximum of 35 tools in a standard configuration: 22 static and 13 live. An exclusively designed automated tool setter checks, measures and sets up tools to optimize the process, allowing shops to reduce setup times from days to hours and regain valuable cut time. A unique high-rigidity base casting creates greater stability, reduced vibration and thermal distortion for increased tool life, enhanced part quality and better surface finishes. A twin-screen
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Chuck Birkle · VP Sales & Marketing at Mazak Corporation. Photo by: Nick Boliek
system with built-in AutoDesk software helps further speed part setups and production. Mazak SYNCREX machines sport the new MAZATROL SmoothSt CNC that features Mazak’s Swiss Setup Assist (MSSA) for fast and easy job setups along with Mazak Turning Chip Control (MTCC) functionality. For further ease of use, the control’s soft key PLC functions include those for tool touch off, part cut off, retract point and start position. MAZATROL SmoothSt also allows for synchronous control, rigid tapping with all spindles and cross and front simultaneous machining. Mazak’s ISO 9001:2015-certified North American Manufacturing Plant in Kentucky produces more than 100 different types Like all Mazak machine tools, SYNCREX of CNC turning centers, Multi-Tasking machines and vertical machining centers, including those from the NEXUS and Vertical machines are backed by Mazak's Traveling Column series. Photo by: Nick Boliek comprehensive 2-year warranty, industryleading MPower complete customer care service and support Multi-Tasking machines and vertical machining centers, including 5-axis program, and lifetime parts availability. models. Continuously investing in manufacturing technology allows the Mazak iSMART Factory™ to be the most advanced and efficient in the
ABOUT MAZAK CORPORATION
industry, providing high-quality and reliable products. Mazak maintains eight Technology Centers across North America to provide local
Mazak Corporation is a leader in the design and manufacture of
hands-on applications, service and sales support to customers.
productive machine tool solutions. Committed to being a partner to customers with innovative technology, its world-class facility in
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Florence, Kentucky produces over 100 models of turning centers,
visit www.MazakUSA.com or follow Mazak on Twitter and Facebook.
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Process
The Great 8 of Manufacturing and Why You Need Them By: Mike Melzer, VP of Operations & Service Global Shop Solutions
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T
oday’s manufacturing customers expect fast turnaround times, competitive pricing, and on-time delivery of quality parts with every job. Achieving these outcomes requires a variety of capabilities called the “Great 8 of Manufacturing.” These consist of the ability to: 1. Move parts through the shop quickly and efficiently 2. Schedule and deliver on time 3. Know your costs 4. Maintain accurate inventory 5. Control your labor costs 6. Get quality right 7. Serve your customers the way you want 8. Grow sales Falling short in even one these areas can impact your ability to deliver what customers want. Problems in several areas make it extremely difficult to compete against manufacturers that achieve all of them on a consistent basis. These Great 8 elements are inextricably linked to each other, and low performance in one area negatively impacts all the others. If you consistently struggle with scheduling, on-time delivery rates suffer. When you can’t accurately determine costs, incorrect quoting can cause you to lose jobs. When shop floor personnel can’t count on having the correct inventory on hand, jobs get delayed, costs go up, and promised due dates are missed. All of which reduces your ability to go head-to-head with leaner, more efficient competitors.
Failure to attain the Great 8 of Manufacturing often results from using outdated manual data collection to manage the shop floor. If you’re still filling out hand-written timecards, using manual spreadsheets to schedule jobs, and tracking inventory by hand, don’t expect a high degree of accuracy in these areas. If you regularly have to schedule overtime or extra shifts to meet customer deadlines, labor costs will spiral out of control. If sales reps frequently walk down to the shop floor to hand-count parts in inventory before confirming a job, you won’t be able to serve customers the way you want. Perhaps the worst outcome is the atmosphere and culture that pervade the shop when key elements of the Great 8 are missing. When the same problems occur over and over again, frustration increases, tempers can rise, and a culture of blame rather than accountability takes over. Is it any wonder that productivity, performance, and profitability take a nosedive in such an environment?
Quote to Cash in One Complete ERP System Making the Great 8 a way of life in your manufacturing business starts with Global Shop Solutions ERP software. Designed for small to medium- size manufacturers, this powerful business management tool digitally tracks, measures and organizes performance data in every area of your shop floor. You can instantly see what’s happening throughout the shop floor in real time and access the data needed to make smart decisions for your business.
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A comprehensive ERP solution, Global Shop Solutions touches all critical aspects of the shop floor so that everything gets better. Automating manual processes enables all employees to work more efficiently and become more productive. Costs and waste decline while sales, margins and product quality go up. You can promise due dates to customers with confidence. Everything comes together in one integrated system so that you really can deliver a quality part on time every time. Global Shop Solutions delivers these outcomes through a complete package of over 25 software applications. Some of the most used applications include: » Planning & Scheduling » Inventory » Job Costing Accounting » Quality Control » Shop Floor Data Collection » Sales » Customer Relationship Management (CRM) Global Shop Solutions is constantly adding new features that enable manufacturers to keep up with the increasingly interconnected Internet of Things (IoT). Some of the most recent IoT enhancements include Electronic Data Interchange (EDI), CAD Interface, and Nesting Interface software. These offer phenomenal time savings and cost reductions by digitally importing job and customer information that would otherwise require time-consuming manual data entry.
To explore all that Global Shop Solutions has to offer, browse our complete list of software modules.
How the Great 8 Transforms Your Manufacturing From Good to Great A manufacturing shop floor is like a jigsaw puzzle. All the different pieces have to come together at the right place at the right time to get the job done. The more complex the job, the more pieces you have to contend with. Each element of the Great 8 represents a key piece in the manufacturing puzzle. If even one is missing, you end up with a big hole in the puzzle. Here’s how they work.
1. Move Parts Through the Shop Quickly and Efficiently. Having access to real-time production data facilitates fast, efficient movement of jobs through the shop floor. When you can schedule based on your true capacity, jobs get started and completed on time. Machinists know which jobs to work on now and next, and no longer waste time hunting down routers, BOMs, inventory lists or other job information in order to get started. Having the right inventory on hand avoids the delays that can occur when waiting for parts to arrive. Electronically importing CAD/CAM, nesting, and customer data eliminates time-consuming double data entry. When bottlenecks occur, the data tells you why it’s happening, allowing managers to take prompt action to resolve them. When you know the up-to-the-minute status of all jobs in production, they get done on time with the quality your customers expect.
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2. Schedule and Deliver On Time. Accurate scheduling and on-time delivery go hand in hand. Global Shop Solutions’ Advanced Planning & Scheduling (APS) module puts you in control with fully automated scheduling. Enter the job and machine data into the router and other modules, and the system automatically schedules the job for you in minutes, transforming one of the most difficult and time-consuming tasks into a model of lean efficiency. With APS, you can finitely or infinitely schedule, balance your workcenter loads, and engage in advanced labor scheduling. When customer changes require last-minute adjustments, you can forward, backward and global reschedule with ease. APS also displays how moving a job around will impact the entire schedule. When multiple jobs get stacked on top of each other due to limited capacity, APS reduces or eliminates these bottlenecks by scheduling the right job on the right machine at the right time. Instead of “safe” due dates, you can tell customers when their jobs will be complete and know you can deliver on time.
3. Know Your Costs. Accurate job costing is one of the most important activities in a manufacturing business, affecting everything from estimating and quoting to cash flow and profit margins. It’s also one of the toughest to get right – unless you track and manage your costs with ERP software.
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Global Shop Solutions automatically assigns the correct cost to all labor, parts and materials that go into a job so you know the exact costs as soon as it is complete. Our innovative FLOOOM product determines individual costing components by measuring freight, labor, overhead, outside services, other and material. With this data, you know exactly how much labor and materials went into a part or job. Knowing your costs improves estimating and quoting accuracy and lets you generate sales and work orders in minutes rather than hours. It helps determine your most profitable products and gives your business a competitive edge over those that can only approximate their true costs.
4. Maintain Accurate Inventory. Delays in production often result from disorganized inventory management.Global Shop Solutions provides real-time inventory data from one point of entry for precise management of materials needed for production. Knowing exactly what you have in inventory and where eliminates the need to hunt for parts to get a job started. Lot bin tracking enables complete traceability of parts. Physical inventory counts are fast and accurate, and often not needed. Paying expedited shipping charges for incoming materials becomes the rare exception rather than a common occurrence. Automatic reorder points ensure materials get ordered before stock runs out, and jobs are never late due to lack of raw materials. With ERP, you’ll never miss another order for materials needed to keep your production line moving.
5. Control Your Labor Costs. ERP software provides complete visibility of one of the biggest line item costs in your business – direct labor. Workers electronically log on to each job and the system precisely measures estimated versus actual labor by job or part. When variation occurs, you can determine whether the problem lies with the machine, the machinist, or other factors. Daily productivity reports help identify problem areas and trend variances so you can take corrective action before they become major problems. Accurate scheduling reduces overtime costs because jobs get completed on time. Downtime costs decline because shop floor personnel always know which job they should be working on. Separately tracking indirect labor categories helps control those with the highest costs. Whether direct or indirect, Global Shop Solutions provides a detailed picture of what employees are doing on and off the job so you can allocate your labor dollars appropriately.
6. Get Quality Right.
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You can’t improve quality unless you can track, measure and analyze the sources of quality problems. Global Shop Solutions’ customizable reporting and statistical analysis tools allow you to track and measure quality information in real time. Nonconforming alerts help identify failure trends as they occur on the shop floor, making it possible to identify and correct bad parts before they go out the door rather than after.
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The Document Control™ module makes it simple to manage quality documentation by consolidating all internal and external documents into one central area. Simply scan each document, assign it a location, and you’re good to go. You can also link technical drawings and job spec sheets to routers, attach inspection and gauge calibration documents to work orders, and attach imported CAD/CAM .pdf files to specific part numbers. No matter what type of quality documents or level of traceability you need, ERP provides an effective solution for managing all your quality information.
7. Serve Your Customers the Way You Want. In today’s mobile manufacturing environment, fast, responsive customer service creates a real competitive advantage. CRM lets you provide the level of service and transparency needed to build profitable long-term relationships with today’s demanding customers by managing and servicing them with accurate, real-time data. Instantly check the status of work orders and open quotes with complete job, part and customer data from one screen. Easily create quotes, generate work orders, and make changes to existing work orders in minutes. Provide answers to customer inquiries in one phone call instead of spending hours chasing down information. Available in the palm of your hand, Mobile CRM helps you deliver superior customer service from the office or on the go.
8. Grow Sales. ERP software provides a complete business management system designed to grow sales. When you schedule jobs more efficiently, it lowers setup and labor costs, improves throughput, maximizes capacity, and increases on-time delivery. These outcomes improve estimating and quoting so you can give customers the best possible price. Efficient scheduling also reduces the time spent putting out fires on the shop floor, allowing more time to focus on generating new business and increasing sales. As a manufacturing business, the ability to deliver on your promises is your biggest selling point. When you give customers a due date and follow through every time, it builds trust. When you deliver quality parts on time every time, sales go up. If you’re struggling to grow sales, let ERP run your shop floor so you can focus on developing new ideas, new products, and new customer relationships.
ABOUT THE AUTHOR: Mike Melzer serves as VP of Operations for Global Shop Solutions and is a 20-year veteran of the company. As a graduate from The Colorado School of Mines, Melzer is an unparalleled leader, coaching the industry’s top talent to ensure the continued success of Global Shop Solutions customers. If you’re ready to gain the Great 8, call Global Shop Solutions at 1.800.364.5958 or set up a demo online at www. globalshopsolutions.com
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Industry Insight
Quick and Easy Simulation of Drives
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ith SINAMICS DriveSim Basic, Siemens presents a new software solution, with which drives and their behavior in machines and plants can be simulated, adapted and optimized. With this new solution, Siemens offers a quick and easy entry into the drive simulation and enables machine and plant manufacturers to accelerate their own development phase. SINAMICS DriveSim Basic bridges the gap between logical and mechanical simulation. The application focus is on simulation support
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34 IMD DECEMBER 2021
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of the customer application, i.e., the components that interact with the drive. The simulation provides answers to drive questions even before a concrete product selection has been made. For the virtual commissioning of the PLC control with known Profidrive telegrams or complex mechanics on the virtual drive shaft, the model provides a reliable representation of the drive system in the required level of detail. One possible application scenario is the coupling of the PLC and the mechanical model via SINAMICS DriveSim Basic. The calculated load profiles can then be loaded into the TIA Selection Tool or SIZER and a drive selection can be made. The
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Power Conversion System for Battery Storage Systems With SINAMICS PCS, Siemens presents a new power conversion system for battery storage applications. The SINAMICS PCS grid converter makes locally generated batter power usable for industrial and public power grids. SINAMICS PCS controls the charging and discharging process of the battery and helps to handle load peaks and grid disturbances via the battery storage, to store the electricity in an energy- and cost-efficient manner, and to bring the energy stored in batteries efficiently and reliably into the grid.
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The grid converter is based upon the industry proven technology of the SINAMICS S120 drive platform and works very energy-efficiently thanks to liquid-cooling. The compact and robust power conversion system includes connection technology and control, line filter, drive and liquid-cooling, and can be easily integrated as a complete system in control rooms or containers. SINAMICS PCS is certified in accordance with the "Technical Connection Rules” VDE-AR-N 4110, which is valid in Germany. This means that stationary battery storage units can be connected to the public medium-voltage grid with minimal system certification effort. A validated Matlab/Simulink simulation model simplifies and accelerates the planning, optimization and grid integration of the power conversion system — and thanks to the SINAMICS Startdrive tool in the TIA Portal engineering framework, the grid converter can be easily integrated into the drive world. Operating states and system parameters can be read out via the Profinet communication interface, which allows data from operation to be monitored and analyzed.
Firmware and Hardware Updates Increase User-Friendliness Siemens is offering new features in hardware and firmware for its SINAMICS S120 drive system. Operation is much easier in firmware V5.2 through the integration of a web-server. The webserver has a new, responsive design and functions via standard web browsers regardless of the device used (notebook, PC, tablet or smartphone). For commissioning typical diagnostics and maintenance functions or
servicing, no special tools are required. The web pages are available in six standard languages and feature error indicators and warning messages including meaningful help texts and suggestions for possible solutions. Users can intuitively create, manage and delete parameter lists — even across axes — and can perform firmware updates and system restores with the old firmware version. Backups of parameter settings can be stored on the clients using the webserver and browser and reloaded in the SINAMICS drive using the Restore function. To test functions that are subject to license, it is possible to activate a temporary trial mode. In addition, a complete overview of all functions that are subject to license is clearly displayed in the webserver. For ideal display on any Internet-capable device, the best browsers are Microsoft Edge, Mozilla Firefox, Google Chrome and Safari. Navigation is easy via menu or bread-crumbs. By simultaneously connecting SINAMICS S120 Active Line Modules (ALM), the operator can now use the Booksize format continuously up to a rated power of 228kW. The simultaneous connection of the 55kW ALM also enables a higher peak power for high dynamic machines than a single 120kW ALM. The space-saving internal busbar can be used by suitable arrangement of the dc link components. 55, 80 and 120 kilowatts (kW) of ALM can be connected in two simultaneous circuits. This feature is supported by the new firmware version V5.2. For specific product information and inquiries, send an e-mail to: mc.us@siemens.com
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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.
Virtually Dust Free Sanding Debuts Under New 3M Xtract™ Brand, Delivering Superior Performance and Enhanced Safety 3M is reinventing the sandpaper game with the introduction of the 3M Xtract™ Cubitron™ II 710W Net Abrasive Disc which provides twice the life and cut rate, while removing up to 97% of dust particles as it sands metal, wood and composite surfaces. All products under the 3M Xtract™ brand promise to "Cut the Dust," helping to give workers a better work environment. This is made possible through a specially designed mesh that extracts dust at every location on the disc. The unique benefit afforded by 3M Xtract™ products is that the technology enhances, rather than compromises, on cutting performance. » For more information, visit www.3M.com
OnRobot Makes Software Debut with WebLytics Solution for Collaborative Applications
Transform Ordinary Pipe into a Powerful Conveyer for Abrasive & Heavy Materials
For end users and integrators, WebLytics not only eliminates manual data collection -- it provides actionable insights into how well a collaborative application is performing, offering live device diagnostics, alerts and preventive maintenance measures to keep costly robot cell downtime to a minimum. Integrating the globally recognized overall equipment effectiveness (OEE) industry standard, WebLytics identifies trends in real-time in the robot cell. OEE measures the percentage of manufacturing time that is truly productive – a score of 100% indicates that the collaborative application is producing only good parts, as fast as possible, and with no downtime.
EXAIR’s new 3 NPT Heavy Duty Threaded Line Vac™ is a powerful in-line conveyor that transports high volumes of material through ordinary pipe. Designed for rugged, industrial applications, it is made of a hardened alloy to prevent premature wear when transporting abrasive or heavy materials like garnet, glass, sand, shot blast, tumbling media or metal fittings. These units feature large throat diameters that make it possible to convey more material over long vertical and horizontal lengths. The conveying rate is typically twice that of ordinary air powered conveyors.
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40 IMD DECEMBER 2021
IMD – The Industry’s Most Extensive Industrial Publication
KHK USA Inc. Announces Extensive Line of Bevel Gears Bevel gears are two intersecting cone shaped gears that are used to transmit rotational motion between them. KHK bevel gears are offered in a broad variety of modules, numbers of teeth, materials and styles, with gear ratios of 1.5 through 5. The angle of intersection may be any angle, but it is generally a right angle. Spiral Bevel Gears have a curved tooth form which provides larger contact surfaces with resulting smoother, less noisy rotation. They are suitable for high-speed heavy load operations » For more information, visit www.khkgears.us/products/bevel-gears
COXREELS Offers New Options for the Challenger Series Reels COXREELS is proud to introduce the new roller bracket assemblies for the Challenger Series. The function of the roller bracket, as it is on other models such as the 1125-Series and the 1175-Series, is to assist in guiding the hose during both extension and retraction. The roller bracket assembly is available only in a 4-way upper roller format, due to the compact size of the Challenger platform. For 12” disk Challenger models, the roller bracket assembly is available for 8” wide drums and 12.5” wide drums. » For further information, visit www.COXREELS.com
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steering control units… offer these advantages: • Minimal steering linkage reduces cost, provides design flexibility. • Complete isolation of load forces from the control station. • Continuous, unlimited control action with low output torque. • Wide selection of control circuits and meter sizes. • Works with many kinds of power steering pumps or fluid supply. gear pumps… Eaton Series 26 gear pumps with 13-tooth gears minimizes flow ripple to reduce noise and vibration. Bearing lubrication system uses inlet oil rather than high pressure oil, improving volumetric efficiency and power output. The 13 available displacements and many mounting configurations provide for an easy retrofit. Other series available. 7355 N. Lawndale Ave., PO Box 6, Skokie, IL 60076
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L&L Ships Box Furnace on a Tight Schedule for Ceramic Applications The L&L model XLE 3636 is a front-loading, refractory-lined box furnace and has an effective work zone of 34” wide by 34” high by 32” deep. There is a horizontal double pivot door with a safety power cutoff switch. A ceramic hearth and standoffs are provided as a workspace for various ceramics and ceramic-based products. The furnace has a series of inlets on the side and an outlet on the top. These can be capped off when not in use to preserve heat, and can provide a “candling” effect where various ceramic byproducts can be removed from the furnace.
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ABB has launched a new family of modular machine tending application cells for the metals industry aimed at maximizing flexibility and machine utilization while minimizing lost productivity caused by unforeseen production stoppages. Featuring six different versions, the FlexLoader™ M family offers a variety of ways of loading and unloading machines based on the size, shapes and amount of the workpieces being handled, making it ideal for applications such as foundries and die casting operations producing multiple types of products in varying quantities. The FlexLoader M Conveyor uses a simple but powerful vision system to enable easy loading of workpieces with complex shapes. » For more information, visit www.abb.com
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42 IMD DECEMBER 2021
Robust Feed U82 Wire Feeder Advanced Process Controls and Extreme Durability The Robust Feed U82 combines the extreme durability of a portable, enclosed feeder and the precision wire feeding and control of a shop-style feeder. Its PreciDrive wire drive system delivers better arc starts and stops without backlash or play in the gears and features a 4-wheel drive system. Large diameter (38 millimeter) drive rolls offer more gripping area and provide more pushing force without deforming soft cored and aluminum wires, a common source of feeding problems. It handles solid wires up to 5/64 in. and cored wires up to 3/32 inch and feeds wire at speeds of 32 to 984 inches per minute. » For more information, visit www.esab.com
FANUC Introduces New Compact LR-10iA/10 Robot – Ideal for Machine Tending and Warehousing/ Logistics Applications Weighing just 46 kilograms, the LR-10iA/10 robot mounts to the floor, upside down, or on an angle. It’s also very easy to mount the robot to an AGV or other mobile platform to accommodate a variety of repetitive tasks or automate machines that are standing idle. The LR-10iA/10 has a 10-kilogram payload and a large work envelope with a long reach of 1101 millimeter. Its compact size makes it an ideal solution for companies with limited floor space, and the slim arm fits into machine tools to load and unload parts. » For more information, visit www.fanucamerica.com
Markforged’s FX20 and New Continuous Fiber Reinforced ULTEM™ 9085 Filament Built to scale distributed global production, the FX20 is precisiondesigned and sensor-driven to deliver breakthrough accuracy, quality, and reliability to fabricate parts directly at the pointof-need with the simple click of a button. As the biggest, fastest, and smartest 3D printer Markforged has ever produced, the FX20 pairs size and throughput to make larger parts at incredible speeds. This new technology, alongside high-temperature printing capabilities, elevates the Digital Forge platform from accessible industrial-strength composite manufacturing to robust production applications. » For more information, visit www.markforged.com
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IMD 43
Surplus Buying and Selling
Stop Industrial Circuit Board Corrosion
Anti-corrosion compound developed for the U.S. military protects against even airborne corrosion accelerators By: Del Williams
T
o produce various products at high-volume, industrial manufacturing plants rely on circuit boards and electronics to precisely and efficiently control the process from the receipt of raw materials onward. Over time, these crucial components can be compromised by processes, chemicals, and airborne vapors that promote corrosion. The result can be costly unscheduled production downtime. “Circuit boards are in everything from electronically controlled valves, starters, motors, turbines, safety switches, boiler controls, and multi-million-dollar digital control systems. These devices are exposed to all manner of corrosive environmental pollutants. Even air-conditioned circuit boards in control rooms filtered with activated carbon can become corroded,” says Bobby Williams, who has a B.S. in Chemical Engineering from North Carolina State University.
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44 IMD DECEMBER 2021
Williams notes that industrial facilities often use corrosive chemicals to process and manufacture various products. Corrosion in controls, circuit boards and electrical systems is further accelerated by exposure to any moisture or humidity. Industrial electronic circuitry is also subject to electrolysis. He points to a Benjamin Franklin quote to illustrate how corrosion is the root cause of much of industrial downtime when not sufficiently addressed: “For the want of a nail the shoe was lost, for the want of a shoe the horse was lost, for the want of a horse the rider was lost, for the want of a rider the battle was lost....” Williams observes that corrosion has long been a fact of life despite the best mitigation efforts of manufacturers. “Even with built-in redundancy and extra spending on materials and protection from the elements, circuit boards and components will corrode and fail anyway,” he says.
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To fight corrosion, industrial plants are turning to a unique military grade compound called StrikeHold® that works as an anti-corrosion protectant, cleaner, and lubricant. This compound was originally developed to preserve, maintain, and lubricate U.S. military weapons and heavy equipment for use in some of the harshest working conditions in the world. Today it is used to protect circuit boards in corrosive environments in industries such as aerospace, agriculture, HVAC, heavy equipment, mining, oil and gas, and maritime operations. The use of StrikeHold has the potential to largely eliminate the effects of corrosion and electrolysis on industrial production equipment. The compound prevents corrosion and electrolysis when applied to systems. The micro barrier that it forms on components is so complete that an electrical charge cannot be passed from the metal into water. It also improves the continuity of the connection when it is applied to both conductors of a circuit. As an anti-corrosive protectant, it sprays on or applies wet and dries in place. A nano film coating protects equipment against the effects of corrosion and moisture while repelling corrosive airborne particles, dust, and dirt. The durable coating is not visible to the eye when it dries and can be reapplied as needed. The protectant is designed to waterproof components as well as dry out wet gear and water-sensitive parts. Because it has a specific gravity greater than water (1.3 vs. 1.0 for water), when applied to a wet surface it penetrates to the hard exterior, pushes water from the surface and coats the area.
“The anti-corrosive compound is designed to make circuit boards, electrical circuits, and metal components virtually impenetrable to corrosion and moisture while improving electrical continuity and contact,” says Williams. He was so impressed with its properties that he became Managing Partner of Force 5 Products, LLC, StrikeHold Brands, a chemical company that has adapted its use to the specific needs of industrial markets. Industries like oil and gas, marine, mining and transportation commonly use StrikeHold to clean systems, deter corrosion and ensure the safe, reliable operation of crucial electronic controls, sensors, valves, and motors. The Metropolitan Atlanta Rapid Transit Authority (MARTA) and Northern Indiana Commuter Transportation District (NICTD), as well as several utilities and EMCs utilize the anti-corrosive product on their electronic circuitry and controls. The Panama Canal Authority has used it on controls and limit switches for years. To obtain material for testing and use or technical information, contact Force 5 Products, LLC: Call Bobby Williams, Managing Director 706-2168224; call 866-331-0572 toll-free; or visit www.strikehold.com/pages/ industrial or StrikeHold at www.amazon.com.
ABOUT THE AUTHOR: Del Williams is a Technical Writer who lives in Torrance, California
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IMD 45
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Ad INdex Accudyne Products USA — www.accudyneproducts.com ............................................................. 9 Actek Manufacturing and Engineering Inc. — www.actekmfg.com ............................................ 37 Air-Vac Systems — www.air-vacsystems.com ..................................................................................38 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ........................................... 5
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KHK Gears — www.khkgears.us ........................................................................................................... 33 Lenzkes Clamping Tools, Inc. — www.lenzkesusa.com ................................................................... 3 L&L Special Furnace Co., Inc. — www.llfurnace.com .....................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ........................... 41 Morgan Manufacturing, Inc. — www.MorganMfg.com ..................................................................49 Pro-Line — www.1proline.com ............................................................................................................49 Radwell International, Inc. — www.Radwell.com .............................................................................. 2 Royal Products — www.mistcollectors.com .....................................................................................49 Scotchman Industries, Inc. — www.scotchman.com ......................................................................17 Select Equipment Company — www.selectequipment.net ..........................................................46 Sprinter Marking, Inc. — www.sprintermarking.com ......................................................................42 Standard Direct — www.Standard-Direct.com ................................................................................ 47 Stor-Loc — www.storloc.com ..................................................................................................... 39, BC The Caldwell Group, Inc — www.caldwellinc.com ......................................................................... 15 Tormach — www.tormach.com .......................................................................................................... 27 Trim-Lok — www.trimlok.com ............................................................................................................. 25
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Wildeck Provides Increased Safety for Moving Palletized Loads OWCASE: URING SH MANUFACT
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» 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
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