IMD | Industrial Machinery Digest January Issue 2015

New software revolutionizes training PLM For extreme testing 6 Challenges for manufacturing indmacdig.com

JANuary 2015

All In One Industrial Supply Chain Solutions Circuit Breakers

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• • • •

OVER A MILLION SQUARE FEET PACKED TO THE RAFTERS WITH MACHINERY & TOOLS 2 OVERSEAS QUALITY CONTROL OFFICES STAFFED WITH QUALIFIED GRIZZLY ENGINEERS HUGE PARTS FACILITY WITH OVER 1 MILLION PARTS IN STOCK AT ALL TIMES TRAINED SERVICE TECHNICIANS AT ALL 3 LOCATIONS • MOST ORDERS SHIP THE SAME DAY

12" X 36" GEAR-HEAD, CAM LOCK SPINDLE, GAP BED LATHE

13" X 40" GEAR-HEAD FLOOR LATHE

• • • • • • • • • • •

• • • • • • • • • • •

Swing over bed: 12" • Swing over gap: 17" Swing over cross slide: 7" Distance between centers: 36" Bed width: 7 1 ⁄4" • Spindle bore: 1 7 ⁄ 16" Spindle nose taper: MT#5 Spindle nose: D1-4 camlock Cross slide travel: 6 1 ⁄4" Compound travel: 3 1 ⁄4" $ 255 Tailstock barrel taper: MT#3 Tailstock barrel travel: 4" Tailstock barrel diameter: 1 9 ⁄ 16" $

• Range of speeds: 70, 200, 220, 270, 360, 600, 800, 1000, 1400 RPM • Motor: 2 HP, single phase, 220V, 8.5A, 60 Hz, 1725 RPM • Height: without stand–23"; with stand–52" • Approximate shipping weight: 1020 lbs.

shipping

lower 48 states

G4003 $2895.00

SALE

279500

Swing over bed: 13" • Range of speeds: 70, 115, 190, 300, 460, 755, Swing over gap: 18 3/4" 1255, 2000 RPM Swing over saddle: 7 3/4" • Motor: 2 HP, 220V, single-phase, 10A Distance between centers: 40" • Size: 71 1/ 2" L x 30" W x Bed width: 7 3/ 8" • Hole thru spindle: 1 7/16" 53 1/ 2" H Spindle nose taper: MT#5 • Approx.

Spindle nose: D1-4 camlock shipping Cross slide travel: 6 1/ 8" weight: Compound travel: 2 7/ 8" 1555 lbs. $ Tailstock barrel taper: MT#3 355 Tailstock barrel travel: 3 3/ 8" $ 00 shipping

lower 48 states

G9036 $4795.00

SALE

3995

14" X 40" 3-PHASE HIGH PRECISION TOOLROOM METAL LATHE

16" X 40" ELECTRONIC VARIABLE-SPEED LATHE

• • • • • • • • • • •

• • • • • • • • • • •

Swing over bed: 14.17" • Motor: 5 HP at 3450 RPM, 2.5 HP at 1725 RPM, 220V, Swing over gap: 20.94" 3-phase • Width of bed: 9" Swing over cross slide: 8.66" • Approximate shipping Distance between centers: 40" weight: 2684 lbs.

Spindle bore: 1.653" Spindle nose taper: MT#5 Spindle nose: D1-5 camlock Cross slide travel: 7" • Compound travel: 4" Tailstock barrel taper: MT#3 $ 355 Tailstock barrel travel: 1.968" Spindle speeds: 16, 50–2570 RPM $ 00 shipping

lower 48 states

G0740 $12,995.00

11,995

SALE

20" X 60" 3-PHASE BIG BORE METAL LATHE • • • • • • • • • • •

Swing over bed: 20" Swing over gap: 29" Swing over saddle: 12" Distance between centers: 60" Spindle bore: 3 1 ⁄ 8" Spindle nose taper: MT#7 Spindle nose: D1-8 camlock Cross slide travel: 12 3 ⁄4" Compound travel: 5" Tailstock barrel taper: MT#5 Tailstock barrel travel: 7" $

G0600

ONLY

• • • • •

755

$

shipping

ONLY

13,500

2495

G0670 $14,995.00

SALE

13,495

• Motor: 2 HP, 110V/220V*, single-phase, 17.8A/8.6A, prewired to 220V • Spindle taper: R-8 • Spindle travel: 4 11⁄16" • Swing: 15 1⁄2" • Max. distance spindle to table: 17 5⁄16" • Collars calibrated: 0.001" • T-Slots: 3 @ 2 1⁄2" on centers, 5⁄8" wide • Table size: 8 1⁄4" x 28 3⁄4" • Table travel (longitudinal): 19 11⁄16" • Table travel (cross): 7 1⁄2" $

G0705 G0760

lower 48 states

00

HEAVY-DUTY MILL/DRILL WITH POWER FEED AND STAND

G0755

shipping

lower 48 states

MILL/DRILL WITH STAND

Spindle speeds: 12, 25–1600 RPM Motor: 10 HP, 220V, 3-phase • Width of bed: 13 3 ⁄4" Range of threads (inches): 60 @ 2–112 TPI Range of threads (metric): 47 @ 0.2–14 mm Approximate shipping weight: 5758 lbs.

• Motor: 2 HP, 220V, single-phase, 1725 RPM, 8.6A • Swing: 20" • Max. distance spindle to table: 18" • Table size: 91⁄2" x 311⁄2" • Table travel (longitudinal): 17" • Table travel (cross): 7 7⁄8" • Head travel: 13 3⁄4" MADE IN AN • Spindle travel: 5" ISO 9001 FACTORY! • Spindle speeds: 90, 210, 345, 670, 1180, & 1970 RPM • Spindle taper: R-8 $ 00

Swing over bed: 16.14" • Motor: 5 HP, 220V, 3-phase with inverter, Yasakawa Swing over gap: 22.95" frequency drive • Width of bed: 10.23" Swing over cross slide: 10.39" • Approximate shipping Distance between centers: 40" weight: Spindle bore: 2.06" 3694 lbs.

Spindle nose taper: MT#6 Spindle nose: D1-6 camlock Cross slide travel: 8.2" • Compound travel: 5.1" Tailstock barrel taper: MT#4 $ Tailstock barrel travel: 6" 495 Speed range: 20–400, 400–2500 RPM $ 00

Drawbar size: 7⁄16"–20 Face mill capacity: 31⁄8" End mill capacity: 11⁄4" Head tilt: 90° left & 45° right Quill diameter: 3" T-slots: 3 @ 31⁄8" on center, 1⁄2" wide • Overall dimensions: 491⁄2" W x 751⁄4" H x 341⁄2" D • Approximate shipping weight: 1102 lbs.

• • • • • •

179

$

shipping

lower 48 states

WITH STAND

ONLY

• Drilling capacity: for cast iron–13⁄16"; for steel–1" • Spindle speed range: 140–2436 RPM • Approximate shipping weight: 848 lbs. * Converting to 110V requires purchase of T25515 conversion kit.

139500

WITH STAND & POWER FEED

ONLY

179

$

shipping

lower 48 states

165000

$

HEAVY-DUTY VS BENCHTOP MILL/DRILL WITH POWER FEED • • • • • • • • • •

Motor: 2 HP, 220V, 3-phase, 6.2A Swing: 20 1⁄4" Max. distance spindle to table: 18 1⁄8" Table size: 9 1⁄2" x 31 1⁄2" Table travel (X-, Y-Axis): 22", 7 1⁄2" Head travel (Z-Axis): 13 3⁄4" Spindle travel: 4 3⁄4" Spindle speeds: Variable, 75–2500 RPM Spindle taper: R-8 Head tilt: 45° left & right

G0762 $2595.00

SALE

• T-slots: 3 @ 31⁄8" on center, 1 ⁄2" wide • Overall size: 49 5⁄8" W x 61" H x 36 5⁄8" D • Base footprint: 17 3⁄4" W x 21 5⁄8" D • Approximate shipping weight: 732 lbs.

249500

$

179

$

shipping

lower 48 states

15INDMA TECHNICAL SERVICE: 570-546-9663 • FAX: 800-438-5901 16971

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in this issue

18

Features

22

28

34

40

cover story

New Software Revolutionizes Training

18

Innovative software from VKS streamlines employee training and improves quality.

22 PLM for Extreme Testing Siemens PLM offers predictable testing for extreme environments.

28 In-Machine Fire Protection Firetrace protects valuable equipment from within stopping fires at the source

34 6 Challenges for Manufacturing Manufacturers face new challenges every day, we examine top concerns.

40 Dual Process Improves Production Eberspaecher concept machine combines rollforming and laser-welding.

Scan this QR-code to learn more

SINUMERIK CNC Anything is possible — when you have the right tools for the job.

Machine tool users who have chosen SINUMERIK CNC can tell you why they love them.

They have watched their productivity increase and trust SINUMERIK CNC systems to make every workpiece an absolute success — whether individual parts or mass production, simple or complex workpieces.

They understand SINUMERIK controls have been setting the standard in the American machine tool industry for more than 50 years and that Siemens continues this innovation.

Do you have what it takes to be highly-productive and highly-efficient?

Isn’t it time to think about whether or not you have the right tools for the job?

Learn how anything is possible with SINUMERIK CNC — scan the QR-code to watch a short video or ask your machine tool dealer for a personal demonstration.

usa.siemens.com/cnc

contents

Publisher, William C. Strickland william.strickland@indmacdig.com 866-833-5346 Associate Publisher, Adrienne Gallender adrienne.gallender@indmacdig.com 888-407-7737 Strategic Accounts Director, Joan Mooney joan.mooney@indmacdig.com 248-613-3792 Account Executive, Clayton Barnette clayton@indmacdig.com

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sections 8

Editor’s opinion

10 Industry Updates 18 Special Focus New software revolutionizes training . . . . . . 18 Siemens PLM For extreme testing . . . . . . . . . . . . . . 22

28 Profile Case Study: Firetrace International . . . . . . . . . . 28

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Editor, Account Executive, Max Kaplan max@indmacdig.com editor@indmacdig.com 336-314-1259 Account Executive, Lisa Hanschu lisa@indmacdig.com 800-366-0676, ext. 114 Art Director / Print Production Manager, Cris Strickland cris@indmacdig.com 800-366-0676 ext. 120 Interactive Product Manager, Sarah Mayo sarah@indmacdig.com 800-366-0676, ext. 112 Audience Development Manager, Jamie Willett jamie.willett@indmacdig.com

Circulation & Subscriptions IMD, 3590-B Hwy 31 South, Suite 233 Pelham, AL 35124 Fax: 877-476-4995 • jamie.willett@indmacdig.com Mailing List Rental Jamie Willett, jamie.willett@indmacdig.com Reprints To purchase article reprints please call 800-366-0676 ext. 103 or email reprints@morethanonesolution.com

34 Market Trend 6 Challenges for manufacturing . . . . . . . . . . . . 34

40 Profile Dual Process Improves Production . . . . . . . . . . . 40

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Editor’s opinion

Shale Gas:

Boom or Bubble?

By Ma x K aplan Comments?

Email Max at max@indmacdig.com

Conflicting information casts a shadow on the promise of a prosperous future powered by cheap, plentiful natural gas.

PricewaterhouseCoopers (PwC) has improved its cost saving and long term employment outlook, citing shale gas production as a significant motivator in the revitalization of the US manufacturing industry. In their recent report titled “Shale Gas: Still a Boon to US Manufacturing?” PwC estimates that the “shale effect” may be responsible for $22.3 billion in savings and 930,000 shale gas driven manufacturing jobs by 2030 – and as many as 1.4 million jobs by 2040.

PwC attributes this optimism to Liquid Natural Gas (LNG) production forecasts published by the Energy Information Administration (EIA) which point to shale gas shouldering the majority of domestic natural gas production.

The improving technology of hydraulic fracturing (fracking) and horizontal drilling have made the challenge of extracting gas and oil from the pores in shale rock strata attainable. Today, shale extraction produces 48 percent of all natural gas mined in the US. While Texas is currently the largest producer of shale gas from its Barnett Shale, extraction operations now focus around the Marcellus and Utica reservoirs. Spanning much of Pennsylvania and West Virginia and parts of Ohio and New York, the Marcellus shale deposit alone is responsible for nearly 20 percent of the United States’ shale gas.

Data reported by EIA suggests that the already robust shale gas industry is growing stronger each year. Production from gas-bearing shale has soared over the past decade from less than 2 billion cubic feet each day to well over 20 billion today. Proved reserves are also trending upward, growing from just 60 trillion cubic feet (tcf) in 2009 to over 159 trillion in 2013. Even more promising are the results of a 2011 survey commissioned by EIA which claims some 750 tcf of underdeveloped shale gas. Called Technically Recoverable Resources (TRR), this gas lies in shale deposits which are already being mined and will require complex re-exploitation using new and emerging technologies to recover. Based on this data, EIA’s 2014 Energy Outlook

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| IMD | January 2015 | www.IndMacDig.com

predicts that production of shale gas will double by the year 2040, becoming the dominant source of LNG. With billions of dollars of investment in new chemical and fertilizer plants over the next few years, reliant on cheap, available natural gas, and positive outlook from industry regulators, shale is shaping up to be the cornerstone for energy independence and a new industrial age in America.

But there are some cracks in these otherwise solid predictions. For example, shortly after the EIA released its report of the vastness of TRR reserves, (450 tcf in the Marcellus reserve alone), the US Geological Survey published a report which estimates the Marcellus Shale to contain no more than 84 tcf of locked-up gas.

An article published in Forbes carries the ominous title “The Popping of the Shale Gas Bubble”. Its author, Bill Powers, has thoroughly researched the shale gas industry.

While the EIA predicts a steady increase in shale gas production year over year through 2040, Powers points out that many production sites are already showing signs of decline. According to Texas regulators, all three shale fields in the state have reached their peak. Reports that Haynesville Shale of Louisiana, touted in 2009 to contain some 1.5 quadrillion cubic feet of gas, have shown to be dramatically exaggerated, with production already down 50 percent from its 2012 peak.

Powers believes that a series of overestimations and unreasonable expectations have created a shale gas bubble which is set to pop long before the EIA-predicted 2040 peak. While US citizens and businesses are set to take advantage of the optimistic report of available, inexpensive natural gas, the reality of a reduced supply in the near future will likely drive prices dramatically higher.

Creating an overreliance on a single fuel source, particularly one so steeped in conflicting data, could be economically disastrous to domestic manufacturing, if the more pessimistic reports about shale gas prove true.

To insure a more stable economy the more prudent approach favors diversification of energy dependence, and a careful look at the magnitude of LNG’s boon for manufacturing in the long run.

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Equipment Purchases Show Strong Growth Leading into Q4 The Equipment Leasing and Finance Association, known as ELFA, reports on economic activity through examination of 25 companies representing a cross section of the Equipment finance sector. Their most recent Monthly Leasing and Finance Index shows an outstanding 9 percent increase in new business volume in October over the same period last year. Year-to-date, cumulative new equipment purchases are up 8 percent. ELFA cites that the growth can be attributed to ongoing growth in the US economy. Margin compression across the manufacturing sector has encouraged businesses to increase volume while also driving investment in new cost-saving technologies.

ELFA has adjusted their monthly confidence interest to 64.2 for November – up from 60.4 in October indicating their positive outlook for the rest of Q4 2014. ELFA President and CEO William Sutton confirmed this prediction saying, “Lower fuel prices, reduced unemployment and a robust equity and bond market all point to a strong fourth quarter, absent some unforeseen development.”

For more information visit www.elfaonline.org/Research/MLFI/

Siemens Adds Functions for CNC Milling and Turning Siemens’ Sinumerik has been augmented with three new functions to streamline and simplify turning and milling operations. Available on the 828D and 840D sl, the new features include a new program management system, plain text reading in the high-speed setting cycle, and a new retraction function.

The Sinumerik Operate program manager has been supplemented with a new feature which allows users to work simultaneously on all connected drives and file structures, and is compatible with more file formats than before.

Operate’s high-speed setting cycle has been enhanced with plain text reading for many machining methods. This setting cycle supports tool- and mold-making applications by transferring machine tolerance. Methods such as roughing, pre-finishing or finishing can now be output as plain text. Orientation tolerance can also be entered.

The new retraction function supports users when retracting a tool following an interruption caused, for example, by power failure or NC reset. Machining can now be resumed from the point of interruption after a manual recovery.

For more information call (800) 879-8079 or email SiemensMTBUMarCom.industry@siemens.com

3D Printing Market Growing Rapidly Analysts anticipate the 3D printing market will grow 20.6 percent between 2014 and 2020, reaching a value of $8.6 billion. These gains are likely to come from increasing demand for the quick and more efficient manufacturing of complexly designed objects using a wide variety of materials.

Additive Manufacturing (AM) is still in its infancy. Though the technology has been around for the better part of thirty years, many improvements have yet to be made. 2014 saw the construction of the first 3D printed automobile at IMTS in Chicago, as well as the development of the large format printer required to make it. Additionally, DMG Mori and Mazak both unveiled revolutionary hybrid manufacturing machines. Combining a laser cladding head and a 5-axis CNC machine in one enclosure, these machines are able of producing a part at near-net shape and perform the finishing operations on that part in the same cycle. While 3D printing has become mainstream in certain corners of the manufacturing industry, many advancements will be required before it sees widespread adoption.

Mazak Unveils Next Generation Smart Factory Yamazaki Mazak has announced that their North American factory in Florence, KY will be the second to receive the iSMART Factory designation. Under the iSMART concept, advanced manufacturing cells and control systems work together through full digital integration to enable complete process monitoring and control. MTConnect® open communications protocol works with process support software to collect and utilize data from every element of the factory.

PCs and portable electronic devices provide real-time access to both management and manufacturing personnel, allowing constant improvement of overall productivity efficiency and responsiveness to customer and market influences. (continues on page 12)

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www.IndustrialMachineryDigest.com | January 2015 | Industrial Machinery Digest |

11

Industry Updates (continued from page 10) “For Mazak, iSMART Factory is a vision – the complete digital integration of the factory with state-of-the-art manufacturing equipment, automation and advanced manufacturing practices. The name establishes a philosophy – a credo of sorts for Mazak that is unique to our operations but symbolizes our commitment toward the ultimate smart factory,” said Brian Papke, president of Mazak Corporation.

Additionally, all the various manufacturing systems in the plant are designed for fast changeovers and allow for production in small lot sizes and with a high mix of components. The systems are also all integrated to the MTConnect® standard, and further advances in 2015 will incorporate the factory floor data with Mazak’s ERP system.

For more information visit www.mazakusa.com/news-events/

Seco Tools Announces New President Seco Tools, LLC of North America has announced Robert Keenan as the company’s new president – to replace Kurt Nordlund effective January 1, 2015. The planned transition promotes Keenan from within the company.

Keenan, currently the Canada country manager and central zone manager for Seco, wields over twenty years of metal cutting industry experience. He owned and managed his own cutting tool distribution business before his sales management career with Seco. ”We have a great team at Seco, with employees who are completely dedicated to partnering with manufacturers to overcome the challenges they face in today’s market,” said Keenan. “Over the coming year, Seco will be introducing many innovative game changing products and digital applications that truly reflect that commitment, and I look forward to leading our organization into the future.”

After seven years, outbound president Kurt Nordlund will move on to a new role as senior advisor where he will manage critical projects and collaborate with company subsidiaries, bringing to bear his considerable industry knowledge to continue to ensure that Seco meets its growth plan goals.

For more information contact Lisa Seidl at 248-528-5444 or lseidl@secotools.com

Mitsubishi Electric’s Machine-to-Cloud Gateway Delivers Real-Time Data Mitsubishi Electric Automation, Inc. and ILS Technology announced a collaboration on the e-F@ctory IoT Gateway. The Machine-to-Cloud (M2C) industrial appliance for Internet of Things (IoT) applications provides seamless connectivity for deviceWISE enabled equipment.

The e-F@ctory IoT Gateway is designed to improve information visibility and accessibility for energy management applications. The appliance processes raw data into actionable information before uploading it to the cloud. Once there, the data is visualized to provide real-time key performance indicators.

“For years, companies have been aggregating data from a variety of devices and storing it in a database its raw format … Rarely is it used to provide any value to the organization,” said Sloan Zupan, senior product manager.

“With the e-F@ctory IoT Gateway, customers can identify which facilities, productions lines, work cells, and shifts are underperforming compared to other areas of the organization.”

For more information visit us.mitsubishielectric.com/fa/en/ or call 847-478-2100

Norican Group to Partner with Altor Norican Holdings ApS has announced its entrance into a binding agreement with Altor Fund IV to sell a majority of its shares to the private equity firm. “This is yet another major milestone for the Norican Group,” says Robert Joyce Jr., President and CEO. “Being able to team with Altor … creates a unique opportunity for us in pursuing the next phase of our strategic evolution.”

Joyce goes on to thank Norican’s previous partner, Mid Europa, for their contributions over the past eight years.

Norican stands to gain significant capitalization and experience from the acquisition, positioning them to achieve their ambitious growth goals.

“Norican is a world market leader in very interesting segments supported by attractive structural growth drivers.

We are very impressed with the business platform that the employees and management team have built under the current ownership and we look forward to supporting the company in its future development”, says Søren Johansen, Partner at Altor Equity Partners.

For more information visit www.noricangroup.com/us or www.altor.com

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| IMD | January 2015 | www.IndMacDig.com

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Industry Updates

TRUMPF opens new facility in Mexico In response to increased business in Mexico, TRUMPF Inc. has opened a facility in Querétaro to better support local customers. The new location will ensure faster response times for parts, sales and support throughout the region, including same day and early morning delivery of crucial parts.

Sofia Cardenas, facility supervisor of the Querétaro warehouse explains, “We are able to stock more than 1000 different part numbers, including spare parts for TruLaser Cell multi-axis laser systems, TruMark marking lasers, and laser resonators.” These parts cover more than 90% of the equipment base in Mexico and will be constantly evaluated to best support TRUMPF customers. Support will be rendered in both English and Spanish.

The facility also includes ample room to host seminars and technical events, ensuring that local prospective and existing customers remain up-to-date on laser technology and applications.

Contact the Querétaro facility at oemspareparts@mx.trumpf.com or visit www.us.trumpf.com

Global Shop Solutions Releases Mobile Administration Application Global Shop Solutions is a leading provider of ERP software for manufacturing. A new mobile app allows system administrators unprecedented access to shop floor and system data, no matter where they’re working. The new app is designed to run on the browser of smart phones, tablets, and other mobile devices.

Although optimized for the smaller screens of mobile platforms, the app presents the same information administrators are accustomed to seeing on their PCs, complete with charts, grids, and drop-down menus for efficient data visualization.

“Global Shop Solutions has enjoyed great success over the years by listening to our customers,” adds Dusty Alexander, CEO for Global Shop Solutions. “They told us they wanted more mobile features to integrate with our software, and we responded. We’re currently working on a CRM-based application that will provide remote access to customer data for sales people and company executives.”

For more information visit www.globalshopsolutions.com

Koma Precision and Hexagon Metrology form Strategic Alliance Koma Precision, Inc. announced a strategic alliance with the Hexagon Metrology M&H product line for the North American market. Starting January 1, 2015, Koma will now be the master importer and system integrator for M&H products. The M&H line includes touch probes, tool setters and laser tool measuring systems for CNC machines.

The new generation of M&H measurement hardware has proven to excel in harsh machining environments with extreme spindle acceleration, constant vibrations and temperature fluctuations while continuing to provide precise measurements.

Koma Precision’s applications engineers will assist customers in selecting the optimum measuring solutions.

Installation services by qualified technicians for the probe and measuring systems will also be provided.

For more information call Janee Agosti at 860-627-7059 or email janee@komaprecision.com

Camfil America Announces New VP Camfil Air Pollution Control (APC), a leading manufacturer of fume and mist collection systems has announced the promotion of Tomm Frungillo to the position of vice president, Camfil APC Americas.

Frungillo has more than 20 years’ experience in dust collection and air filtration. He has held a succession of posts in sales management as well as special market management in the pharmaceutical, mining and thermal spray industries.

“Tomm Frungillo has been a key player in the growth of Camfil APC since he joined the company in 2000,” states Alan O’Connell, executive vice president in charge of global operations for the company. “He will assume full responsibility for the Jonesboro manufacturing facility as well as sales operations in North and South America for all Camfil APC products, including the full line of products resulting from the Handte acquisition earlier this year.”

For more information call 1-800-479-6801 or email filterman@camfil.com

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| IMD | January 2015 | www.IndMacDig.com

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| IMD | January 2015 | www.IndMacDig.com

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www.INDMACDIG.com | January 2015 | IMD |

17

Special Focus

New Software Revolutionizes Employee Training Visual Knowledge Share is an investment in manufacturing’s greatest asset – its workforce.

By Ma x K aplan

The browser-based software can be used on stationary and mobile devices.

18

M

odern software is able to provide advancements and cost savings on nearly every front of the manufacturing industry. Resource planning programs allow top-down control of an entire business.

Manufacturing Execution System (MES) software allows in-depth monitoring and control of a production environment. Advances in CAD software are giving the individual designer more ability than an entire engineering team two decades ago. CAM programs are letting manufacturers get the most out of every operation from every machine. But none of these software solutions can improve the abilities and culture of the workers they rely on – that requires a new approach entirely.

The workforce itself has been a pressing issue in manufacturing as the industry endures an ongoing labor shortage. Veteran workers are aging out, and new skilled workers able to replace them are hard to find. The Obama Administration has pumped nearly $2 billion into community college initiatives to increase the availability of manufacturing skills – a logical step designed to reduce unemployment while strengthening the industrial sector.

And it may be working. Census Bureau data from 2012 indicated that only 5.4 percent of plant managers pointed to lack of skilled workers as a cause for facility underutilization. But this data does not take into account the current growth of the manufacturing sector nor the rapid aging of the current workforce.

Ultimately, the shortage of skilled workers is only half of the problem. Ask any facility manager, and they will tell you that their troubles don’t end when a new hire signs

| IMD | January 2015 | www.IndMacDig.com

on the dotted line. Weeks or months of costly training are required for a new employee to be able to work independently and effectively. The expense of paying a new, unproductive employee is compounded by the time spent by a veteran worker in training the recruit, diverting the company’s best resources away from production and toward a new hire who may not be successful.

Facing attrition among their existing workforce and with limited options for acquiring new trade workers, many shop managers are left with an important question: how do I best utilize the knowledge and experience of my existing workforce to train new hires while maintaining quality and remaining competitive within the marketplace?

Quebec based Visual Knowledge Share (VKS) has a solution. Their unique, standalone teaching and performance measuring software bridges the gap between the individual worker and the ERP, MES, and MRP programs which govern a manufacturing environment. Image-based instruction sets are created and displayed to workers to guide them through virtually any production process, all the while collecting vital performance and quality control data for display to supervisors. VKS has all the tools to bring new employees up to speed, instilling best practices without diminishing the production of veteran employees.

Visual Knowledge Share operates on stationary terminals or portable devices (like tablets) through a browser-based interface. Customers can choose to either purchase a monthly subscription for the software, which is then hosted on VKS’s own servers, or make a one-time investment to purchase the software and host it on-site. Monthly solutions

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Special Focus come in three varieties with different capabilities, but all come with 25 user accounts. Packs of 10 users can be added to the base package to accommodate operations of any size.

To use the program, a worker logs in with his or her own account. He or she then selects the operation to be performed, and the program automatically gathers the most up-to-date instructions for that task. A form is then displayed requiring the user to input information about the specific job, such as part or order number. This data can be input manually, scanned via runner barcode, or synchronized from a connected ERP program. Steps are displayed to the user sequentially and can be progressed manually, by timer, or by wireless communication with certain tools. Any interruption in workflow triggers an automatic alert to the appropriate supervisor so the problem can be fixed quickly and without interruption to other processes.

Forms can be inserted into the instructions which require user interaction. At a certain stage of a job, the program might be configured to require measurements of critical dimensions in order to ensure that parts are being produced to the required specifications. VKS is also capable of wireless integration of measurement tools. A wireless digital caliper, for example, can interface with the software to allow measurements to be taken and recorded seamlessly, making quality control throughout a given process fast and effortless. All quality data is reported to manager-level accounts which have access to performance information based on part number, order number, employee, etc. Any quality check failure can be configured to alert managers immediately.

Instruction sets are created using VKS’s fully-featured instruction creator. Images can be uploaded or taken as needed, captions and arrows added, and text inserted to develop clearly defined steps and processes. VKS states that each step requires about two minutes to build. The versatility of the instruction creator means that steps can be defined for any job possible within a manufacturing environment. Welding, machining, cutting, bending, finishing, assembly, packaging, quality inspection – any of these can be laid out in an easy-to-use digital manual for use by any employee.

A sample instruction might work as follows. 1) An assembly worker logs in and selects the instruction set for an assembly which has arrived at his station. 2) He scans the barcode on the paper runner – information about

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| IMD | January 2015 | www.IndMacDig.com

the particular assembly and the order with which it’s associated are automatically loaded into the VKS form. 3) The timer starts automatically as he views the first step. He is instructed to load the unfinished assembly into a jig – this process is known to take no more than 25 seconds, and the next instruction is displayed automatically after that interval.

4) The next step instructs the worker to apply specific torque to three bolts on the assembly. Using, for example, an Atlas Copco STwrech, the worker tightens each bolt and the exact torque values are reported wirelessly to the VKS terminal. Only once the correct torque is applied does the instruction allow the user to move on to the next step. Each torque value is stored for reporting purposes. 5) During the next step, the user runs out of a particular fastener. He has to spend several minutes acquiring the needed parts.

VKS knows that his current step should have taken no more than 75 seconds, and after a predetermined interval, his supervisor is notified of the delay. 6) The supervisor comes by the stalled workstation and finds that no issues require his attention. 7) The remaining steps proceed without incident. 8) The final time is recorded by the software.

VKS is designed for efficiency and transparency, to improve workflow and quality control at all stages of a process for employees new and experienced. Many small and medium shops are looking to make the leap into digital plant management, only to find whole-factory solutions prohibitively expensive. VKS bridges this gap, placing real time instruction, data collection, and quality control within reach of any facility. VKS also includes a complete API, allowing it to interface directly with ERP, MRP, and MES software solutions.

One of many successful VKS implementations, Clearpath Robotics has been thoroughly impressed by the performance of the software. Process Engineer Manager Jaron Lefler had this to say about VKS “We put VKS to the test about 4 weeks ago. Our average test and assembly time on a Turtlebot with an experienced tech is 30-40 minutes. I had my work cell set up. I gave our brand new never-seena-Turtlebot-in-his-life co-op student a tablet and a login. He pressed play and followed the instructions without needing to ask any questions. You know how long it took him to assemble the robot?

32 minutes. If we diligently document assembly instructions, we can nearly eliminate training altogether. It is wonderful. It makes our production so scalable. All we have to do to produce more is add a computer and bring in labor.”

VKS offers a unique combination of versatility, functionality and affordability. As competition grows and margins shrink, shops of all sizes will require new tools to keep themselves ahead of the curve. With flexible purchasing options, unprecedented scalability, applicability to any process and full customization, this unique software is a powerful tool with applications reaching far beyond the factory floor. Visual Knowledge Share is a clear choice to keep your shop competitive in this challenging job market.

For inquiries, contact Jill Graham at 855-201-4656 or jgraham@vksapp.com

Taking an innovative approach

special focus

Predictable Testing for

Extreme

EnvironmentS

Siemens PLM software provides a stable environment for testing critical components of Europe’s nextgeneration launch platform.

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| IMD | January 2015 | www.IndMacDig.com

Just a few days before the maiden flight of the new European Space Agency (ESA) Vega launcher, Marc Pitz (who is responsible for testing) and Marc Rigal (production engineer) at SABCA noted that they did not know if the electromechanical thrust vector actuation system from SABCA, which would be used to steer the rocket ship that took off from the French Guyana Space Center in Kourou, would perform according to plan. A few days later, the first qualification flight of the Vega launch vehicle proved to be a success.

“The outcome of the Vega program is extremely important for us,” says Pitz. “Vega will mark our future.”

SABCA is one of the main aerospace companies in Belgium. It was founded in 1920 and is based in Haren, near Brussels, and Charleroi. Besides being a subcontractor for different aircraft manufacturers, such as Dassault Aviation and Airbus, SABCA just delivered its 100th Airbus A380 T-Shape: a large metallic structural assembly that carries high fuselage loads between the main wheel wells of the aircraft. The company also builds servoactuators for the Ariane 5 launcher and the interstage 0/1 skirt and the thrust vectoring systems for the four stages of the new Vega launcher.

This new Vega launcher has been developed by ESA during the last nine years. It will be able to bring a 1.5ton payload into low earth orbit. The technology on the Ariane 5 program goes back as far as the early 1970s, and the servo-actuators that were used to direct the rocket thrust and steer the rocket ship are still electrohydraulic systems: GAT (Groupe d’Activation Tuyère) and GAM (Groupe d’Activation Moteur).

For the new Vega launcher, SABCA followed a very innovative approach by developing a fully electrical thrust vector-actuation system (electromechanical actuators, control and power electronics and the associated software). This system is based on a proprietary SABCA microprocessor hardened against space radiation. It will operate in a vacuum at very low temperatures and have to withstand the heavy shocks generated by the separation of the various stages of the rocket.

Due to significant constraints, the thrust vector actuation system undergoes a very strict and severe qualification test program during development. But each subassembly also undergoes a set of predefined lower and shorter tests on the shaker just before rocket assembly.

Appreciating versatility

Five years ago SABCA decided to replace and update its first system, and now uses LMS Test.Lab™ software in combination with LMS SCADAS™ hardware for closed loop shaker control and data acquisition from Siemens PLM Software.

“We evaluated different suppliers, and the solutions of Siemens PLM Software offered far more possibilities and flexibility, mainly because of their modal capability,” says Pitz.

Two years ago, the test environment was further enhanced with a brand new 160 kilo Newton (kN) shaker, referred to by Pitz as ”our big elephant.”

“We use the same test setup for both qualification and production testing of the servo-actuators,” says Pitz. “This built-in flexibility is considered a key advantage of the

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23

special focus

Siemens PLM Software testing solutions.

“Ease of use is very important to us because different engineers are using the system, and not everybody is a test software expert or can invest vast amounts of time studying the tools. Production engineers are no vibration experts, but once the configuration is set, they push the button and the test is done. These time savings are important for us.”

Providing accurate control

Siemens PLM has proven itself in many critical applications. Red Bull-Renault, a UK-based F1 racing team, relies on Siemens PLM for design and development.

The SABCA engineering team performed thermal tests and basic vibration tests on the actuators, mainly of the sinusoidal and random type.

“During the qualification tests, the components are put under severe stress, up to 22.5 g in sine mode and 20 g in random mode,” says Rigal. “During production, test levels are topped off at 12 g in random mode. Production tests are mainly focused on random mode.

“A vibration test on a hydro-mechanical actuator typically takes half a day,” says Pitz. “Since it takes two actuators to steer the thrust of an engine, tests are performed on two hydro-mechanical actuators consecutively, as a twin configuration. So testing one set takes a day, plus two days for the thermal test.”

“Starting from the primary parts, it takes three to four weeks to have a hydro-mechanical actuator ready,” says Rigal. “Producing an electromechanical actuator takes less than a day, but far more time to test. The test cycle takes more time than the assembly cycle.”

Controlling risks during these tests is important because safety is a critical consideration.

“Testing actuators means that the level on the hydraulic pump needs to be limited to a max of 250 g, especially when reaching resonances,” says Rigal. “We control this level accurately because harmonic and peak estimators are computed in real time by the software.”

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| IMD | January 2015 | www.IndMacDig.com

SABCA used Siemens PLM software to test the durability of the electromechanical thrust vectoring system of the European Space Agency's new Vega launcher.

Integrating testing and simulation

“We perform about 15 to 20 vibration tests per month,” says Rigal. “We’ve used the system for five years, and during that time we’ve never experienced any unexpected or unstable behavior of the system.”

The development of the Ariane 5 launcher predates virtual testing and testing models. Although numerous tests were performed and data were gathered, no truly correlated virtual test model of the hydro-mechanical actuator was ever built. Since the beginning of the Ariane 5 program, the technology of servo-actuators has undergone a major change.

The actuators on new Vega are electromechanical, which follows the recent trend in this area. Testing these electromechanical actuators means entering unchartered territory.

“This electromechanical character complicates vibration testing in a certain way, because besides mechanics, we also have to test the electronic components on a small board inside the electronic box,” says Pitz. “Resonance frequencies are a lot higher with electronic components.

Exposure of these components to space radiation also means that we have to perform electromagnetic compatibility tests.” It is believed that testing and simulation will be further integrated in the future. “We believe that simulating testing using correlated models will be required in the future in order to better predict the vibration behavior during the qualification test,” says Pitz.

The use of the virtual shaker technique will increase confidence in the test and enhance the notching profile definition.

“Mechatronic actuators are quite a new product, including for us,” says Pitz. “Testing has become more detailed and delicate. For the moment, the mechanical and electronic parts are still separated, but in the near future, the electronics will be integrated on the mechanical parts, thus actuators will become truly integrated mechatronic systems.”

For more information visit http://www.plm.automation. siemens.com/en_us/

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Every PCNC 1100 Series 3 features: • Table size 34” x 9.5” • R8 Spindle 1.5 hp variable speed 5000 RPM and 90 IPM axes motion • Computer controlled spindle speed and direction • Standard G code compatibility • Composition bonded slideways (similar to Turcite®) When compared to the risk and headaches of used equipment, the decision is easy.

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Why You Need Case Study:

Fire Protection A

s any shop owner can tell you, the reason to buy a CNC or EDM machine is not to make parts, but to make money. Whether they are financed or purchased outright, CNC and EDM machines are a shop’s “bread and butter” and must be kept up and running to maximize profitability. That’s why the risk of a machine fire, and the associated losses from costly repairs, unscheduled downtime, and in some cases catastrophic business interruption, is a major cause of concern for every machine shop owner and manager.

The risk of a machine fire is greatest when straight-oil metalworking fluids are used during machining operations.

Straight-oil fluids have relatively low flash points ranging from 400° F to 600° F (204° C to 316° C), and are widely used for high tolerance medical, dental, military, and aerospace machining operations. Straight-oil metalworking fluids are continually exposed to extremely high levels of friction and heat; a single spark can cause volatile oil vapors to flash over in an instant. These kinds of fires require extremely fast action in order to prevent damage to the machine and to

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| IMD | January 2015 | www.IndMacDig.com

protect personnel and surrounding areas of the facility.

Many shop owners rely on their employees to fight machine fires. However, even when employees are properly trained in firefighting procedures, they may be unwilling or unable to deal with an actual fire. Machine oil fires produce intensely high heat and dense black smoke that can make them difficult or impossible to fight with a handheld fire extinguisher. In some cases machine doors may be interlocked during the production cycle which inhibits the operator’s ability to fight the fire; if the operator does open the door, the resulting in-rush of oxygen can cause the fire to grow frighteningly out of control. The reality is that a machine fire can be a terrifying event that can unnerve even the best trained employee, leaving a shop at risk until the fire department arrives.

According to one reputable source, more than 10 percent of all CNC machines using straight-oil metalworking fluids will experience a fire event within five years of installation. Even when an automatic sprinkler system is present, a machine fire can result in costly repairs and

How the Firetrace System Works CNC Cutting, Milling, Turning and Grinding Machines

• For CNC applications a Firetrace Indirect Low Pressure (ILP) 3M™ Novec™ 1230 Fire Protection Fluid system is usually recommended.

• The red detection tubing is routed throughout the work zone which improves reaction time and reduces the potential for machine damage.

• The detection tubing can also be run to the front the machine when an optional manual release is required.

• Large nozzles deliver a high volume of Novec 1230 to quickly suppress the fire.

Die Sinking EDM Electronic Discharge Machines

• For EDM applications a Firetrace Indirect High Pressure (IHP) CO2 system is usually recommended.

• The red Firetrace Detection Tubing is routed around the base of the ram just above the typical operating oil level, providing 360 degrees of fire detection and suppression.

• The detection tubing can also be run to the front the machine when an optional manual release is required.

• Large nozzles installed well above the oil surface on both sides of the ram deliver a high volume of CO2 to extinguish the fire. The CO2 is delivered as a gentle mist to keep the burning oil from splashing, which would spread rather than suppress the fire.

• Firetrace indirect low pressure (ILP) systems are available with a manual release, enabling an operator to activate the system at the first sign of trouble.

significant losses from unscheduled downtime. A machine fire has the potential to spread through mist collectors and along ducting to the building’s structure, often with catastrophic results. Worst of all, a machine fire may tragically lead to employee injury or death.

In this article we’ll look at some of the causes of machine fires and what you can do to protect against them.

The Challenge

All turning, milling and grinding processes pose a fire risk when using oil-based metalworking fluids. An oil fire can occur in an instant without warning. The friction from a dull tool, a spark from a hot metal chip, or a crash from a programming error are just a few of the many situations that can cause oil-based metalworking fluids to ignite.

Each year hundreds of machine shops suffer substantial damages from attended machine fires; the potential for a disaster increases exponentially when a shop runs “lights out” or unattended. An oil fire can damage or destroy a machine in less than a minute: left unchecked, the amount

of damage can devastate a business.

The direct cost of a fire, such as machine and facility damage, can range from tens to hundreds of thousands of dollars; the collateral costs from long-term disruptions can lead to the loss of business, as customers form relationships with new vendors, which can ultimately bankrupt a company.

About Sprinkler Systems

In the United States, most jurisdictions require an automatic overhead sprinkler system for machine shops, based on National Fire Protection Association (NFPA) standards. Automatic sprinkler systems are designed to give occupants in the building time to evacuate and to protect the building’s structure; they are not designed to protect a shop’s equipment or assets.

In cases when a sprinkler system activates, the damage caused by water can be as destructive as the fire itself. A single, quick response sprinkler head can discharge 13-24 gallons of water per minute; an entire sprinkler system can cause massive flooding that can result in extended

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29

Profile The Clean Agent Advantage

downtime. Prolonged downtime can cause more than just cash flow problems; it can lead to irreparable loss of business as customers migrate to other vendors.

Sprinkler systems are designed to activate when exposed to high heat; since oil fires start inside machines, a CNC machine would have to be completely engulfed in flames to cause a sprinkler system to activate. This can lead to the total destruction of the machine and give the fire time to grow to the point where it can spread to adjacent equipment or the building’s structure.

This is not to say that sprinkler systems are without merit; there’s doubt that they save lives and property.

However, you cannot count on a sprinkler system to protect your machines and equipment. That kind of protection requires a supplementary fire suppression system designed to protect CNC and EDM machines and other high value and/or mission critical assets.

Containing the Threat

Adding an automatic fire detection and suppression system is a reliable and cost-effective way to protect your CNC and EDM machines against the threat of fire and the revenue losses caused by machine damage and downtime.

One system, invented by Firetrace, utilizes unique, pressurized, heat-sensitive tubing as the detection (and in some cases delivery) device. This proprietary polymer tubing is a linear pneumatic heat sensor that bursts at the point closest to a fire’s radiant heat. The tubing is very flexible and can be easily routed in and around the hazard areas of a CNC or EDM machine, providing fast and reliable fire detection in areas that other detection methods cannot reach.

Because Firetrace detects and suppresses a fire at its source – inside the machine – the system reacts far faster than traditional fire suppression methods. Unlike most competing detection systems, Firetrace tubing can react to a fire in less than 10 seconds, which reduces or eliminates machine damage and downtime. In many cases a machine can be returned to service just minutes after a fire once the problem has been corrected.

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Some fire suppression systems use foam, dry chemicals, and even water as fire extinguishing agents. More advanced fire suppression systems use “clean” fire suppression agents such as 3M™ Novec™ 1230 Fire Protection Fluid, CO2 (carbon dioxide), and DuPont™ FM-200®. These clean agents are designed to quickly extinguish fires resulting from the ignition of combustibles used in machining operations.

Clean agents are dispersed as a gas, which allows them to quickly permeate inside a CNC machine. It also makes them uniquely suited to protect the electronics inside the equipment. By thoroughly flooding the interior of a CNC machine with a gaseous clean agent, even hard-to-reach fires can be quickly extinguished, often before they can be seen.

Clean agents work on class A, B, and C fires and react quickly to suppress a fire at its earliest stages. They are electrically non-conductive and non-corrosive, so they will not contaminate machine bearings or expensive metalworking fluids. Clean agents are environmentally friendly and non-toxic and are safe to use in areas where shop employees are working. Most importantly, clean agents leave no residue and require no cleanup, so a machine can be back up in running in a very short time.

Titanium Fires

Fires sparked by flammable metals, such as titanium, are classified as Class D fires. Class D fires are a unique hazard because they burn at very high temperatures and react violently with water and some chemicals. Given sufficient heat, titanium powder and shavings can ignite and burn, posing a serious fire hazard for machining operations and can quickly spread to other combustibles. Titanium also presents an explosion hazard.

Fires involving combustible metals such as titanium are best handled by the fire department. Remember that water should never be applied to a titanium fire because it creates an explosive situation!

One key measure for avoiding titanium fires is to detect and suppress an oil fire quickly, before the heat can build to the flashpoint of titanium. It is not a total solution, but one important step toward preventing titanium fires.

Summary

When shopping for an automatic fire detection and suppression system, keep in mind that all brands are not created equal. The best systems bring fire detection and suppression inside the machine, in order to quickly detect and extinguish a fire at its source.

Look for a system that uses Novec 1230, CO2, and FM-200 fire suppressing agents. These “waterless” clean agents will allow you get your machine back up and running in the least amount of time without concerns about residue cleanup or oil and bearing contamination.

Adding an automatic fire detection and suppression system allows for a constant “24/7 fire watch” on your machine. Even when the operator is away or you are running lights out, an automatic fire detection and suppression system will provide the peace of mind that comes with around-the-clock machine fire protection.

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Suitable for power source 100V-277V AC Accommodates 24V AC/DC Consists of 1 LED bulb x 3W Protection against water, lubricants, coolants, dusts and other liquids Special design for fast heat dissipation Furnished with 1.8 meters cord with plug (For 100V-277V only) Flexible goose neck arm covered with sleeve Built-in transformer Approvals: CE, IP65

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market trend

Challenges Facing Modern Manufacturing Companies often require the ability to track where specific items have been used or to trace materials from an end-item at a customer site back to specific materials used in its manufacture.

Companies in highly regulated industries, such as medical devices, are facing new regulations including UDI (Universal Device Identification) and ePedigree requirements, while chemical and electronics manufacturers deal with REACH (Registration, Evaluation, Autorization, and Restrictions of Chemicals) and similar laws. Keeping abreast of regulations and managing compliance reporting is often a full-time activity for multiple people or teams at many manufacturing companies.

Keeping products relevant

M

anufacturing is an ever-changing industry, where manufacturers face new issues and concerns every year. Since this year is no exception, here are a few of the top concerns that manufacturers are grappling with.

Regulatory compliance and traceability

Nearly every type of manufacturer faces increasing regulations aimed at everything from ensuring product safety to managing disposal and reclamation procedures.

While many regulations may be beneficial to consumers, each regulation adds an additional burden to the companies that must comply with the requirements, which often differ from country to country.

Manufacturers must ensure they have complete visibility into global supply chains so they can prove not only their own compliance, but also that of their suppliers. Regulations

34

| IMD | January 2015 | www.IndMacDig.com

Product innovations come at a dizzying pace, and manufacturers struggle to keep up. As companies vie to be first to market with a new concept, the temptation to skip steps or skimp on quality materials can be overwhelming.

Companies need to plan to have adequate engineering time to ensure that the specifications for critical materials such as wires and cables are in line with operating conditions. The last thing a new product needs is to develop a reputation for poor quality right out of the gate.

Fast times to market mean that companies may need to become more systematic about managing innovation rather than leaving new product ideas to chance. Product preferences change so quickly that delays in introducing new ideas may be the death knell for once popular products.

Implementing procedures that keep a steady stream of new product ideas and innovations in the pipeline is essential to manufacturing success.

Aging workforce / Skills gap

As baby boomers reach retirement age in record numbers, they are leaving the workforce and taking their hard-won skills and experiences with them. Younger workers are not readily available to replace these retirees, and those that are available don’t have the necessary skills for many critical roles.

Manufacturers may need to work with schools in their

designers and builders of hydraulic products and custom assemblies power units… As designers and builders of custom hydraulic assemblies, MacMillin offers solutions for both your system and physical requirements.

Wide range of capacities and components to suit every application. Both horizontal and vertical configurations.

form your own inserts

circuit-block manifolds… With MacMillin

“Circuit Blocks”, numerous valves and controls can be plugged in to a single space-saving manifold. Eliminates troublesome plumbing problems, such as leaking or broken hose and pipe connections, that can cause system failure.

pump motor mounts… Strong lightweight aluminum alloy castings completely enclose motor shaft and coupling, providing greater safety and quieter operation.

Assures accurate alignment without bedplates, brackets or shims. Fractional to 200 hp motors.

Formdrill’s form sturdy bushings that can be threaded to produce your own inserts. These built-in inserts are as strong or stronger as the same-diameter welded nuts. Process works in steel, stainless steel, copper and aluminum up to ½” thicknesses.

Standard UNC, UNF, NPT and Metric sizes are available up to 1.5” in diameter. It can easily be used in most Drill Presses, Milling Machines and CNC systems.

7355 N. Lawndale Ave., PO Box 6, Skokie, IL 60076

Phone: 847-676-2910 Fax: 847-676-0365 www.macmhydraulic.com

Formdrill USA Inc

773-290-1040 info@formdrill-usa.com www.formdrill-usa.com

www.INDMACDIG.com | January 2015 | IMD |

35

market trend

workers are not readily available “ Younger to replace . . . retirees, and those that are available don’t have the necessary skills for many critical roles.

”

communities to ensure that the educational system includes the topics and skills training those younger workers need to fill these roles. In addition, manufacturers may need to be more flexible with their aging workforce, allowing workers to slow down by working part time rather than retiring abruptly. This phasing to full retirement meets the needs of baby boomers and allows them to pass on their skills to following generations of workers.

Healthcare costs

Rising costs of healthcare for workers put a strain on already fragile manufacturing cost structures. Manufacturers in the U.S. in particular face the burden of providing healthcare while their competitors in other countries do not.

There is no strong alternative to the current solution on the horizon, so manufacturers need to be cognizant of this large and growing item that can increase the cost of products to the point where they are not competitive.

Environmental concerns

Many local and regional regulations affect various aspects of the manufacturing process, from the ability to use certain materials, to worker exposure, to disposal of waste and byproducts.

Manufacturing is inherently a harsh environment, so ensuring the safety and health of workers with proper care and equipment is of crucial importance. Disposing of waste

36

| IMD | January 2015 | www.IndMacDig.com

products and recycling programs for scrap and returned materials add costs and complexity to manufacturing, but also result in a healthier environment and protection for customers and workers alike.

Balancing maintenance with throughput

Keeping equipment functioning is an essential part of running a manufacturing facility. Regular preventive maintenance, including replacing worn wires and cables, can help increase throughput and ensure customer satisfaction with delivery lead times.

Sometimes manufacturers are tempted to postpone or delay preventive maintenance or they replace factory components with lower-quality items. This practice may create unsafe conditions in harsh manufacturing environments if these lesser components can’t stand up to operating conditions. For example, poor-quality or worn cable and wires can result in risk of shocks or electrocution for workers in the worst case, or they may simply cause unplanned or excessive downtime. Using components, cables and wires that meet or exceed manufacturer specifications and performing preventive maintenance on recommended schedules keeps operating costs low and throughput high while helping to ensure worker safety.

Addressing these challenges means that manufacturing companies need to stay current on legislation as well as technology and to be responsive to worker needs while acting responsibly in the best interests of all parties.

Danielle Iera is the Marketing Coordinator of TPC Wire & Cable Corp. (http://www.tpcwire.com/) in Macedonia, OH. TPC Wire and Cable’s products are designed and engineered to withstand harsh industrial and manufacturing conditions like flexing, harsh chemicals, extreme temperature, high impact and abrasion.

iso 9001: 2008 Registered firm

High Speed Drilling & Tapping Units High Speed Drilling & Tapping Units High Speed Drilling TappingHeads Units • Drill & Tap Feed Units • & Multi-Spindle • Drill & Tap Feed Units • Multi-Spindle Heads • Lead Screw • Clutch Tappers • Drill & Tap FeedTapping Units • Multi-Spindle Heads • Lead Screw Tapping • Clutch Tappers Servo Driven Ball Screw RailTappers Units • •Lead Screw Tapping • Clutch • Servo Driven Ball Screw Rail Units • Servo Driven Ball Screw Rail Units

DRILL. TAP. REPEAT. DRILL. DRILL. TAP. TAP. REPEAT. REPEAT. Engineered Tough for Year After Year Reliability Engineered Tough for Year After Year Reliability Engineered Tough for Year After Year Reliability

YouR souRce foR sAfe And eAsY lifting solutions Mold Handler™ Swivel & Pivot Hoist Rings

Forged Street Plate™ Swivel Hoist Rings

Side Load Hoist Rings

Drop Forged Hoist Rings

Round Base Swivel & Pivot Hoist Rings

Forged Swivel Hoist Rings

Hoist Ring Kits

Hypneumat.com Hypneumat.com Hypneumat.com 414-423-7400 414-423-7400 414-423-7400

0° 18 ts vo

Pi

Swivels 360°

Hoist Rings ARe:

200% Proof Load Tested Each Ring Has Serial Numbers Orders Shipped Same Day Rated load 400 lbs - 250,000 lbs

cAll foR fAx foR A fRee cAtAlog 1110 Fullerton Rd, City of Industry, CA 91748 Phone: 800-752-7229 or 626-581-3424 Fax: 626-581-3423 Email: sales@actekmfg.com

www.Actekmfg.com

www.INDMACDIG.com | January 2015 | IMD |

37

Hydra Service, Inc luid Mov Specialist in F em ent Wastewater Pumps, Grinder Stations, Process Equipment, Generators, Motors & Panels, ABS, Godwin, Toyo, Yamada, Aeration Industries, AMWELL, IronBrook Partners

Warrior, AL, 800-749-3569 • Pelehatchie, MS, 888-258-1892 Robertsdale, AL, 800-847-5006 • Debary, FL, 800-323-1731

www.hydraservice.net

NEW UNITS. REMAN UNITS. PARTS. REPAIRS. WE’VE GOT YOU COVERED. Whether your equipment lifts, spins, flips, cuts, presses, injects or just moves, you can rely on Hydraulex Global’s hydraulic products and services to deliver the performance and reliability you need to keep your equipment going. We stock, as well as have the experience and expertise necessary for repairing and rebuilding piston, vane and gear type pumps and motors, valves, servo & proportional valves, cylinders and orbital motors, for most any industrial application.

Manufacturers we stock and repair. � Bosch/Rexroth � Vickers � Continental � Kawasaki

� Sundstrand � Staffa � Eaton � Parker

� Racine � Abex � Moog � Denison

1.800.422.4279 www.hydraulex.com

www.ahx1.com

© Hydraulex Global. All Rights Reserved.

38

Connect with us:

| IMD | January 2015 | www.IndMacDig.com

� Atos � Pegasus � Oilgear � and more

t u r n - k e y s o lu t i o n s s i n c e 19 8 9

rotor rebuilding lamination refurbish/replacement servo Motor repair core loss testing

Ac Motor repair Dc Motor repair Dynamic Balancing Field services

3021 Standridge rd. • anderSon, SC 29625 • email: imSinfo@induStrialmotorServiCe.Com

864-226-2893 • 864-232-0216

www.industrialmotorservice.com

ROLL-FORMER/ LASER-WELDER

profile

Improves Production

TWINMASTER machine from Weil Engineering combines a destacker, roll former and laser welder to produce various lengths and shapes. Eberspaecher uses these machines to make stainless steel catalytic converter cans and other exhaust/silencer system components for many major auto builders.

The Siemens SINUMERIK 840D, a powerful CNC, controls all the operations on the machine. Once programmed, the blank will be processed through each stage in the machine; all controlled by the 840D and Siemens SIMODRIVE 611D drives package onboard.

40

T

he installation of a unique concept in metalforming at Eberspaecher North America has improved their production by 20%.

Eberspaecher N.A., based in Novi, Michigan, is a Tier-One supplier of complete exhaust systems. They manufacture stainless steel catalytic converters and exhaust products required by its impressive list of automotive customers, including Chrysler, Dodge, Jeep, Pontiac, Buick, Chevrolet and Mercedes-Benz. Founded in 1865 and in the automotive exhaust business since 1931, this German-based company has operated facilities in the USA and Canada since 2000. It currently manufactures in Brighton, Michigan, as well as Tuscaloosa, Alabama and Brampton, Ontario.

For their new catalytic converter production line, Eberspaecher N.A. elected to install a laser-welding shorttube production cell. At the heart of this system is a “Twinmaster” roll-forming and laser-welding production system supplied by Weil Engineering North America of Troy, Michigan, which is a subsidiary of Weil Engineering GmbH. of Muellheim, Germany. Currently, Weil Engineering has over 60 tube forming and welding systems in operation in North America, most of them using lasers for welding application. Sixty percent of Weil Engineering’s business activities are in the automotive fields, followed by HVAC,

| IMD | January 2015 | www.IndMacDig.com

chimney, household appliances and motor shell applications.

The “Twinmaster” combines two major functions in one machine: roll-forming and welding. Secondary processes such as blank feeding and post-welding expansion of tubes for perfect roundness are directly linked to the “Twinmaster”, creating one complete production center. The control functions for the entire system are supplied by SIEMENS, using a SINUMERIK 840D for CNC controls and a SIMATIC OP170 operator panel for dialog functions. The HMI is configured by Weil Engineering in “ProTool” for the particular performance requirements of this unique production system.

The production capabilities of this short-tube manufacturing system are: • Min. and max tube diameter: 3” to 8” • Min. and max. tube length: 8” to 50” • Tube shapes: Round or oval • Wall thickness range: 0.020” to 0.080” • Materials: Mild and stainless steels • Output: up to 500 parts/hour • Welding speed (3.2 kW laser) 4-5 meters/min

The sequence of operation is as follows: Two sheet-metal destackers, mounted on a rotary æ

table, are loaded each with approx. one hour’s production material and feed the blanks into the rollformer. The blanks are inspected for double-sheet condition during the transfer movement. Once the first destacker is empty, the rotary table moves the second destacker into place and the first one can be re-loaded, ensuring a non-stop supply of material.

Depending on the length of the tubes, multiple æ

blanks (up to 4) can be rolled into tubes during the same machine cycle.

The rolled tube blanks are automatically transferred æ

from the roller to the seam welder, where they are automatically clamped and butt-welded using a laser-beam generated by the Trumpf TLF 3200 laser.

(TIG welding is another option for this process, being more economical in cost initially, but also slower in welding speed compared to laser.).

Once the welding process is done, the finished cans æ

are extracted from the tooling and transferred onto an inline weld annealing system, which heats the welding zone to approx. 1000º C (~ 1800º F) to relieve the stress in the welded seam.

æ

After a cooling section, the CNC-controlled handling system introduces the cans into a hydraulically operated tube expander, where they receive a pre-selected inside dimension. This final dimension is calculated from the diameter of the converter substrates, the thickness of the insulation mats and the spring-back of the stainless steel material used for the converter cans.

The sequences of these operations, the exact timing for each process and the control of all movements are monitored and operated by a SIEMENS SINUMERIK 840 D controller.

The Siemens CNC also monitors the position, the power and the on/off condition of the laser beam, as well as all the transfer mechanisms and the tooling. According to Weil Engineering’s service manager, Matthias Philipp, “The open architecture and substantial power of the CNC make it possible to easily monitor and control all these various functions. We also produce our own HMI protocols for the CNC and PLC on the operator panel. The Siemens system makes this much easier to accomplish.”

Onboard the Twinmaster, the Siemens CNC technology controls eight rotary axes, with the SIMODRIVE 611U drive package on the destacker and chamfering device. Another 611U operates four axes on the expander and handling system. With the Profibus field bus system pioneered

by Siemens, all CNC, PLC, HMI and drive systems can communicate in a more reliable fashion. This permits one CNC program to be written, and then adapted by xthe machine builders, such as Weil Engineering, to modify

(clockwise) From the Siemens SIMATIC PLC operator panel, each step in the TWINMASTER process is monitored and controlled. Weil Engineering uses ProTool software to custom configure the HMI on the machine.

Drawing station Bending station Laser station

Some of the shapes produced on the TWINMASTER machines.

their controls based on the particular functionalities of their equipment. In this case, for example, two analog outputs are utilized for power and sequencing to control ramping, on/off and other parameters of the laser. The TRUMPF laser on the Twinmaster machine has a 200mm optics bifocal mirror with a constant focal length. When the material thickness changes, the CNC tooling varies the position of the work piece.

For more information visit www.usa.siemens.com/cnc, e-mail SiemensMTBUMarCom.sea@siemens.com, or call 847-640-1595.

www.INDMACDIG.com | January 2015 | IMD |

41

surplus buying & selling

FEDERAL KNIFE, INC. Industrial Cutting Knives

P.o. Box 509 • 785 County line road • Palmyra, in 47164

REPLACEMENT SHEAR BLADES DELIVERED FROM STOCK Precision Blade Sharpening Is Our Specialty!!

Shear Blades For All Equipment Makes: • CinCinnati • Wysong & Miles • HtC • aCCur-sHear • PaCifiC • aMeriCan HerCules • niagara • Pexto • aMada steelWeld / Cleveland Crane • BetenBender • atlantiC / HaCo • lodge & sHiPley / ColuMBia • Century • Herr-voss • standard • edWards / Pearson • adira • gatti • lvd • di-aCro / elga-Hydra • HydraPoWer • staMCo • BertsCH • guifil • safan • darley • rHodes • Morgan • suMMit • dreis • & Many otHers

Shear blades made from high quality tool steels “performance matched” to your unique cutting application.

Call one of our product specialists for more information.

WE WILL BEAT ANY

competitor’s quoted price for new replacement shear blades by 5% OR MORE GUARANTEED*

www.federalknife.com sales@federalknife.com • 812-364-1448 * PRESS BRAKE TOOLING * METAL SLITTERS * SLITTING SUPPLIES * 42

| IMD | January 2015 | www.IndMacDig.com

WEBSITE

www.raco.com

for specifications & photos on over 1000 machines in our inventory!

MORI SEIKI #SL65A CNC Turning Center, Fanuc 16T, 4.1" Sp. Bore, Chuck, Tailstock, Chip Conv., 50 HP, 1996

#273A CINCINNATI HEALD Internal Grinder, Ext. Bed, 3 Red Hd. Sp., Chuck, Tooling, 5 HP, 1977

104" X 3/4" AKYAPAK Hydr.

4 Roll Plate Bending Roll, #AHS16/20, PLC Touch Screen, Hydr. Drop End, 20 HP, 2004

13.8" x 40" STUDER CNC Cylindrical Grinder, #S35R, Fanuc 16T CNC, 20" x 3-1/4" Wheel, Cool/Filtr., 10 HP, 1988, Retro. & Rebuilt by Studer 2000

138 Ton AMADA CNC Press Brake #FBD1253NT, Upacting, Hydr. Amada AMNCB 7 Axis CNC, 118" O.A., 106" B.H., 5.9" Stk., 15 HP, 1999

OKUMA #ES-L8 CNC Turning Center, OSP-U10L CNC, 8" Ck., Tailatock, Chip Conv., 10 HP, 2000

88 Ton AMADA CNC Press Brake #FBD8025NT, Hydr., Upacting, Amada AMNCB 7 Axis CNC, 98" O.A., 85" B.H., 5.9" Stk., 10 HP, 2000

MAZAK #FJV35/80 Bridge Type CNC Vert. Machining Center, 78.7"X, 31.5"Y, 23"Z, Cat.50, Mazatrol M Plus, 40 ATC, 6K RPM, Tooling, 1998

10" x 10" AMADA #HA250W Automatic Horiz. Band Saw, 1-1/4" Blade, Hydr. Vises, Chip Auger, 5 HP, 1993

40/52" x 80" SUMMIT Hvy. Duty Lathe #40DC, 5-1/2" Sp. Bore,

MIGHTY VIPER #VMC1270A CNC Vert. Machining Center, 4th & 5th Ready, 50"X, 25"Y, 25"Z, Cat 40, 8K RPM, 20 ATC, 2003

5.1" TOSHIBA Tbl. Type Horiz.

Boring Mill #BFT-13W2, 48" x 98" Tbl., 98" Cr., 71" Vert. #50 Tpr, P.D.B., D.R.O., Way Bed, Pendant, 1975

JUST PURCHASED

56" BULLARD Dynatrol CNC VTL, Fanuc 11TT, Turret & Side Hds., 48" Vert., 3 Jaw, 50 HP 56" BULLARD Dynatrol Vert.

Boring Mill, Ram & Side Hds., 60" Under Rail, 3 Jaw Ck w/4 Jaws, 60 HP, 1968, Excellent

20" x 20" AMADA Horiz. Band Saw #HFA 500S, Auto. Cycle, 2" Blade, 2 Hydr. Vises W/Bundling, 7.5 HP, 1996 OKK #MCV820 CNC Vert. Machining Center, 63"X, 32"Y, 28"Z, Cat.50, OKK GMC CNC, 30 ATC, 25 HP, 1995 7.8"x11.8" TSCHUDIN CNC Cyl. Grinder #PL24, Usach Open Arch. CNC, Marposs P5 Gauging, SBS Balancing Sys., 10 HP, 2001, CNC Upgrade 2014, From Medical Device Mfg. 6" MITSUBISHI CNC Floor Type Boring Mill, Ram Type, 393"X, 78"Y, 27.5"Z, Fanuc 18i CNC, 60 ATC, 1988, Retro. 2001 42"/62" x 108/180" LEBLOND Hvy. Duty Sliding Gap Bed Lathe, Taper, D.R.O., 3 Chucks, 4 St. Rests, 25 HP, 1958

8' X 19" OOYA Radial Drill #RE3-2500, #5 MT, 2150 RPM, Coolant, Box Tbl., 15 HP, 1976

OKUMA #MX-45VAE CNC Vertical Machining Center, 30"X, 18"Y, 17.7"Z, 7K RPM, OSP700M CNC, 20 ATC, 2000

FADAL #VMC6535-50 CNC Vert. Machining Center, 65"X, 35"Y, 34"Z, 50 Tpr., Siemens 810D CNC, 7500 RPM, 32 ATC, 45 HP, 2005 FRYER CNC Bed Type Vert.

Mill, #MB14, 3 Axis CNC, 40"X, 20"Y, 25"Z, 40 Tpr., Anilam 1400 CNC, 5 HP, 1998 (3)

www.INDMACDIG.com | January 2015 | IMD |

43

surplus buying & selling

we want to buy your surplus or underutilized machinery!

We buy single machines or entire plants and are always looking for: • Late Model CNC Machines • Hardinge Machines • Fabricating Equipment • Toolroom Machinery

Email or call us today! sales@actionmachinery.com

610.691.6677

www.actionmachinery.com a leading distributor of Quality machine tools & fabricating eQuipment 2320 highland ave., bethlehem, pa 18020 (ph.) 610-691-6677 (fax) 610-694-0944

44

| IMD | January 2015 | www.IndMacDig.com

Call, Email or go onlinE for morE dEtails and a full invEntory list

2023 BlaCk BridgE road york, Pa 17402 fax: 717-845-9497

717-846-2600 • SALES@HILDEBRANDMACHINERY.COM • WWW.HILDEBRANDMACHINERY.COM 400 MACHINES IN STOCK • INSPECT UNDER POWER • 30 DAY RETURN PRIVILEGE

66” Bullard cnc VTl, Rebuilt & Retrofit 1999, Fanuc 16T CNC

Toyoda HMc, Fa-450II,

17” Pallets, Fanuc 15M, New 1997

62” dorrIes scHarMan VTl, Manual w/ 2008 Fagor CNC Control

BFP 130/6, 18’ x 8’Y, New 1980

5” unIon Floor Type HBM,

5” TosHIBa HBM, 98” TaBle,

WaHlI dIxI HMc, 4 axIs,

KITaMura MycenTer 2xI sparK cHanger,

Haas VF5, 23” x 52” TaBle,

12” Pallets, Fanuc 15MB, New 1995

72” Y, New 1978, Have 2

Cat 50, New 1998

14” x 22”, New 2001

5” g&l HBM, 70-5d-T,

86” Table, 60” Y, New 1965

BrIdgeporT VMc 1000xp2,

22” x 45”, 8K rpm, Fanuc 18iMB, New 2004

We are actively buying good used machines of all types. turn your idle machines into cash

www.INDMACDIG.com | January 2015 | IMD |

45

surplus buying & selling

• APPRAISALS • FINANCING • • TRADE-INS • TOOLING •

• SHIPPING • INSTALLATIONS • • TRAINING • SOFTWARE •

www .jor Visit us TO V dancraig at IEW A CO machine r MPL ETE y.com LIST

Machinery Dealers National Association

4000 WATT AMADA FO3015MII RI LASER CUTTING SYSTEM WITH ROTARY INDEX, MFG:2011 - 11,348 HOURS (10120)

4000 WATT AMADA FO3015NT M2 LASER W/6 SHELF AS LUL 300 AUTOMATIC, MFG: 2012 (Mach 10161)

33 TON AMADA PEGA 367 TURRET PUNCH W/ FANUC O4PC CNC CONTROL, MFG: 1992 (9987)

22 TON AMADA AE255NT SERVO DRIVEN TURRET PUNCH, MFG: 2014 (Mach 10154)

33 TON AMADA VIPROS III 3610NT HIGH SPEED HYDRAULIC TURRET PUNCH PRESS, MFG: 2004 (Mach 10153)

187 TON X 167” AMADA HFE 1704S/7 “DOWN-ACTING” HYDRAULIC CNC PRESS BRAKE, MFG: 2000 (Mach 10135)

6000 WATT AMADA LC-3015F1NT LASER CUTTING SYSTEM, MFG: 2011 (Mach 10114)

5200 WATT BYSTRONIC BYSPEED 3015 LASER SYSTEM, MFG: 2005 (10072)

25 TON TRUMPF TC5000R-1600 CNC PUNCHING MACHINE, MFG: 2005 (Mach 10159)

4000 WATT AMADA GEMINI F0-3015 CNC LASER CUTTER W/HIGH SPEED HS2003 HEAD, MFG: 2002 (Mach 10156)

2500 WATT AMADA PULSAR LC2415NTA4 LASER, MFG: 2008 - INSTALLED NEW:FEBRUARY 2010 - APPROXIMATELY 5,900 HOURS (10067)

187 TON X 160” TRUMPF TRUMABEND V170 PRESSBRAKE W/ DELEM CNC BACKGAUGE W/PROGRAMMABLE Z1 & Z2 HYDRAULIC CLAMPING, CROWNING, MFG:2000 (10013)

Jordan Craig Machinery Int’l LLC 151 N. Main St. Ste 203 • P.O. Box 737 • New City, NY 10956 Tel: 845-398-0073 • Fax: 845-398-0074

jc@jordancraigmachinery.com • www.jordancraigmachinery.com

46

| IMD | January 2015 | www.IndMacDig.com

www.INDMACDIG.com | January 2015 | IMD |

47

surplus buying & selling

Buy, Sell, Rent New & Used We make it easy to sell your surplus equipment.

Send us a picture. We will promptly call you back with our best offer.

HEAD & TAIL STOCK

WELDING MANIPULATORS

POSITIONERS

FLAT TURN TABLES

WE HAVE MOVED TO A NEW LOCATION Billing Address: P.O. Box 3255 • Spring, Texas 77838 Shipping Address: 321 North Loop East • Houston, Texas 77022

email: sales@weldingequipment.com P: (713) 694-1790 • F: (713) 694-1791 • C: (281) 380-9607

WWW.WELDINGEQUIPMENT.COM 48

| IMD | January 2015 | www.IndMacDig.com

TURNING ROLLS

THE PERFECT LITTLE TOOL ROOM FURNACE

melmor melmor Associates, inc.

• Extremely Uniform • Easy Lift Door Only $3950 • Program Control Model GS1714 • 17"W x 14"D x 12"H

Associates, inc.

“World’s Largest Material Handling Distributor” “World’s Largest Material Handling Distributor”

20 Kent Rd • POB 2129 • Aston PA 19014

877.846.7628 • www.llfurnace.com Problems with machining of tough alloys?

     

Wire Baskets Wire Baskets Hoists Hoists Pallet Racking Pallet Racking Conveyor Conveyor Rolling Ladders Rolling Ladders

Since 1963 Since 1963      

Steel Containers Steel Containers Self Dumping Hoppers Self Dumping Hoppers Shop Pans Shop Pans Warehouse Carts Warehouse Carts Plastic Containers Plastic Containers

Habcool 318: for tapping, drilling, broaching, reaming, and threading. Dramatic increase in finish and tool life. h&b Petroleum company Call for a free sample 973-664-0144 www.habcool.com

Melmor Associates, Inc. Melmor Inc. OH 44446 840 Ann Avenue - POAssociates, Box 511 - Niles, 840 Ann Avenue - PO Box-511 - Niles, OHfax 44446 330-652-1784 phone 330-652-1667 330-652-1784 phone - 330-652-1667 fax www.melmor.com www.melmor.com

KOSTER IS IN 2 ONLINE ONLY AUCTION SALES! SALE 1 TUCKER TECHNOLOGIES Online Bidding Ends: Thursday, January 8th at 2:00 P.M. (EST) Inspection: Wednesday, January 7th from 8:00 A.M. to 4:00 P.M. (EST) 2540 Mountain Industrial Blvd., Tucker, Georga 30084 FEATURING: CINCINNATI 3-SPINDLE 5-AXIS CNC VERTICAL GANTRY PROFILER MILLING MACHINE, WITH 160’’ X 90’’ TABLE, 75’ LONGITUDINAL GANTRY TRAVEL, 20’’ VERTICAL HEAD TRAVEL •SNK SHIN NIPPON KOKI MDL. FSP-100-H; SNK SHIN NIPPON KOKI MDL. PC-60V 5-AXIS CNC HORIZONTAL MACHINING CENTERS • CLEARING NIAGARA MDL. T-4900-106 900 TON CAPACITY STRAIGHT SIDE PRESS • (5) SEIKI-XL MDL. 3VX 3HP – AS NEW AS 1997, (2) BRIDGEPORT SERIES I 2HP; (2) BRIDGEPORT SERIES 2J 1-1/2HP; BRIDGEPORT SERIES J VERTICAL MILLING MACHINES • GEKA MDL. HYDRACROP 50A HYDRAULIC 50 TON CAPACITY IRONWORKER • PULLMAX TYPE P5/2 UNIVERSAL SHEARING & FORMING MACHINE • OKAMOTO MDL. ACCUGAR-124N POWER FEED SURFACE GRINDER • BOYAR SCHULTZ MDL. 2A SIX TWELVE DELUXE; OKAMOTO MDL. 6-18; HARIG SUPER 612 HAND FEED SURFACE GRINDERS • TOS NOSTIVAR MDL. BN102A TOOL & CUTTER GRINDER • BROWN & SHARPE MDL. 9-12-9 XCEL DCC 5-AXIS; BROWN & SHARPE VALIDATOR COORDINATE MEASURING MACHINES •O.G.P. MDL. OQ30UP OPTICOM QUALIFIER 30’’ OPTICAL COMPARATOR • RABOMA MDL. 12U1600 12’’ X 78’’; OOYA MDL. RE1225H RADIAL DRILLS • TOYOTA MDL. 5FGC30 5250#; CLARK MDL. C500-80-0 7500# FORKLIFT TRUCKS •BAND SAWS • COLD SAWS • MARKING MACHINES • TAPPERS • WELDING POWER SUPPLIES • TOOLROOM •ASSORTMENT OF ROTARY TABLES • LARGE QUANTITY OF SHOP SUPPORT • PLUS MUCH MORE!

SALE 2 SIGMA MANUFACTURING INC. Online Bidding Ends: Wednesday, January 14, AT 2:00 P.M. (EST) Inspection: Tuesday, January 13th from 8:00 A.M. to 4:00 P.M. (EST) 1361 East Bay Street, Bronx, New York 10741 FEATURING: 2008 KIWA KH-45G 4-AXIS CNC HORIZONTAL MACHINING CENTER, 12,000 RPM WITH 7,400 HOURS • (2000) FADAL VMC 6030; ENSHU VMC530 CNC VERTICAL MACHINING CENTERS • MATSUURA MC-500V-DC; MATSUURA MC-760V-DC 4-AXIS CNC TWIN SPINDLE VERTICAL MACHINING CENTERS • ALSO: TSUDAKOMA 4TH AXIS ROTARY TABLES • DAEWOO PUMA 10S; DAEWOO PUMA 8 CNC TURNING CENTERS • SUMMIT MDL. SWB400X1500 18”/22” x 56” GAP BED LATHE • ACRA TURN MDL. 1340 13” x 40” ENGINE LATHE • SUPERMAX VERTICAL MILLS • K&T MILWAUKEE HORIZONTAL MILLS • BLOHM MDL. HFS512 20” x 80”; ELB MDL. RS-15/60 23”x 59”; GIBSON 8” x 24” HYDRAULIC FEED SURFACE GRINDERS • NORTON MDL. LC2 18” x 120”; EASTON 8” x 14” CYLIDRICAL GRINDERS • MARVEL SPARTAN PA10/3 HORIZONTAL BAND SAW • HONE• WELDERS • INDUCTION MELTER • AIR COMPRESSORS • FORKLIFT TRUCKS - UP TO 10,000# • LARGE QUANTITY OF INSPECTION ITEMS • SHOP SUPPORT • PLUS MORE!

www.kosterindustries.com

Register to bid live on-line thru:

View our website for brochure, terms & conditions. Buyers premium will apply.

Phone: 631-454-1766 • www.kosterindustries.com

www.INDMACDIG.com | January 2015 | IMD |

49

surplus buying & selling

EEL specializes in large and hard to find fittings. Stocking through 6” in most items.

EEL is a master distributor of Penn Union Corp. with the most extensive inventory on the East Coast.

Recyclers of Surplus Electrical Supplies

Buyers & Sellers of Electrical Supplies

Your source for hard to find electrical supplies and every day items at bargain prices!

CIRCUIT BREAKERS (NEW) GE - THQP, THQL, THQB, TEY, TED & MISC SIEMENS - BL, BQD, BQ, QJ, ED, FD, FXD, JD, JXD, HJD, PUSHMATIC & MISC CUTLER HAMMER - BAB, QBHW, GHB, ED, EHD, FDB, FD, HFD, HMCP & MISC SQUARE D - QO, QOB, EDB, EHB, FA, KA, LA, MA & MISC

CONDUIT & ELBOWS EMT - IMC - RIGID STEEL ALUMINUM PVC COATED GREENFIELD PVC SEALTITE THRU 6"

50

Phone: 215-236-1160 Fax: 215-235-5339 800-523-3818 www.eastelec.com CONDUIT BODIES

APPLETON - BRIDGEPORT CROUSE HINDS - KILLARTK OZ GEDNEY - RACO RED DOT - ROB ROY

CONDUIT FITTINGS

GREENFIELD/MC CONNECTORS

APPLETON - BRIDGEPORT CROUSE HINDS - OZ GEDNEY PLM - RACO - THOMAS & BETTS

LUGS & CABLE CONNECTORS

APPLETON - ARLINGTON BRIDGEPORT - CROUSE HINDS KORNS - MYERS - OZ GEDNEY RACO - THOMAS & BETTS

PENN UNION CORP - BURNDY DOSSERT - ILSCO - 3M THOMAS & BETTS

FUSES

PVC FITTINGS

BUSSMAN - CEFCO - EDISON FERRAZ SHAWMUT LITTELFUSE

CANTEX - CARLON - KRAYLOY

CABLE TIES

CUTLER HAMMER - GE SIEMENS - SQUARE D WESTINGHOUSE

PANDUIT - THOMS & BETTS

| IMD | January 2015 | www.IndMacDig.com

SAFETY SWITCHES

STRUT FITTINGS

B-LINE - GLOBE STRUT POWER STRUT - SUPERSTRUT UNISTRUT - VERSABAR

WIRING DEVICES

ARROW HART - BRYANT HUBBELL - KELLEMS - LEVITON PASS & SEYMOUR - WOODHEAD

MISCELLANEOUS

3M COLD SHRINK, TERMINATIONS & TAPE BEAM CLAMPS *MALLEABLE) BELL BOXES - BUS DUCT PLUGS CADDY - CADWELD - ENCLOSURES ERICSONS - LOCKNUTS PLASTIC BUSHINGS - STEEL CITY TRANSFORMERS

Select

equipment

Industrial Electrical Sales

MCC BuCkets & Motor Control Centers Custom Built mCC BuCkets • largest inventory in the midwest!

we Can retrofit any make and model of mCC BuCket with all new Components inCluding vfd’s! soft starters nema & ieC starters

888-459-5191 • sales@selectequipment.net

www.INDMACDIG.com | January 2015 | IMD |

51

classifieds classifieds

SMARTIE

1-2-3 or 4 Camera Drive Recorder * * * * *

Continuous + impact save video View 4 views together on PC GPS location + 3 axis impact Saves video to up to 32GB SD Lockable box protects SD card

buying? selling?

We buy & sell Wire mesh, steel & plastic

containers m h containers Phone: 440-951-4900 Fax: 440-951-2711 info@mhcontainers.com

WWW.mhcontainers.com

52

| IMD | January 2015 | www.IndMacDig.com

Fab & Metalworking 4.5x4.5.pdf

1

11/19/14

10:57 AM

nOw a part Of rOckfOrd-ettcO prOcunier Our Bench, Horizontal, Floor and Automated Machines are used throughout the Stamping, Die Casting, Screw Machine, and CNC Parts Manufacturing Industries.

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#1: SURPLUS TO THE ONGOING NEEDS OF A MAJOR AUTO CONTRACT MANUFACTURER ONLINE AUCTION ENDS: Thursday, January 15th, 2015 at 11:00am (EST)

ASSET LOCATION: 3604 Glendora Rd., New Troy, MI • INSPECTION: Wed., January 14th, 8:00am to 4:00pm (EST) FEATURED EQUIPMENT: MORI SEIKI NL1500SY CNC Lathe w/Gantry Loader & Stacker New 2005 • EUROTECH 730 CNC Lathe w/Live Milling New 1996 • DAEWOO V15 3-Axis CNC VTL w/Live Tooling New 1998 • OKUMA V60RM VTL w/Live Milling New 2007 • DAEWOO DHP-630 HMC New 2001, TOYODA FA400 HMC New 1999 • TOYODA FA450 HMC New 1993, MITSUI SEIKI HT4A HMC New 1995 • MITSUI SEIKI HS4A New 1995 • Tooling & Accessories • ITEMS LOCATED OFFSITE: (2) Haas’ SL-30T’s, (2) Mazak QT280’s, (1) Mori Seiki SL-154Y/500, (1) Haas Mini-Mill, Plus much more!

#2: SURPLUS TO THE ONGOING NEEDS OF A MAJOR CONTRACT AEROSPACE MFG. ONSITE & ONLINE AUCTION: Thursday January 22, 2015 at 11:00am (CST)

LOCATION: 910 S. Morgan Rd., Oklahoma City, OK • INSPECTION: Wed., January 21st, 8:00am to 4:00pm (CST)

OFF-SITE SNK PM-6 DUAL GANTRY 5-AXIS PROFILER NEW 1998 SNK PM8-A 5-AXIS GANTRY NEW 1981

HAUNI-KOLB VARIMAT VG 5-AXIS CNC GANTRY TYPE MACHINING CENTER

160” X-AXIS

5-AXIS FLOW 5-AXIS WATER JET SYSTEM NEW 1993

RAMBAUDI RAMMATIC 1400 VMC

FEATURED EQUIPMENT: SNK PM-6 Dual Gantry 5-Axis 3 Spindle Profiler New 1998 • SNK PM8-A 3-Spindle 5-Axis Gantry New 1981 • FLOW 5-Axis Water Jet System New 1993 • MAZAK FJV 60/120 VMC New 1999 • HAUNI-KOLB Varimat VG 5-Axis CNC Gantry Type Machining Center New 1999 • MITSUI SEIKI HJ-100A 4-Axis HMC New 1999 • MITSUI SEIKI HR7A 5-Axis Horizontal Boring Mill New 1980 • MAZAK H630 Cell New 1990 • SHODA NC291-6721 CNC 4 Spindle Gantry Type Router New 1988 • (2) MODIG MD7200 CNC Profile Machining Centers New 1998 • RAMBAUDI Rammatic 1400 VMC w/160"x60"x43" • HAAS VF-3 VMC New 1994 • MORI SEIKI SL-6 CNC Turning Center New 1981 • MAZAK M4 CNC Turning Center, Milling Machines • Huge quantity of #50 Taper Tooling

For More Info. & Complete Photo Gallery go to: www.machinerynetworkauctions.com call (818) 788-2260 or email info@machinerynetworkauctions.com

ONLINE BIDDING AVAILABLE

www.INDMACDIG.com | January 2015 | IMD |

53

advertiser

& Web Site Locator

Actek Manufacturing and Engineering Inc......................37

Grizzly Industrial, Inc............................................................ 3

MachineryStreet..................................................................45

xwww.actekmfg.com

www.grizzly.com

www.machinerystreet.com

Action Machinery................................................................44

H&B Petroleum ..................................................................49

MachineTools.com..............................................................50

www.actionmachinery.com

www.habcool.com

www.machinetools.com

Air-Vac Systems...................................................................35

H&K Equipment, Inc............................................................45

MacMillin Hydraulic Engineering Corporation.............35

www.air-vacsystems.com

www.hkequipment.com

Haco-Atlantic, Inc................................................................19

AmCon Design & Contract Manufacturing Expo..........................................52

www.hacoatlantic .com

www.amconshows.com

Hilco Industrial, LLC...........................................................47 www.hilcoind.com

Attica Hydraulic Exchange................................................38 www.ahx1.com

Hildebrand Machinery........................................................45 www.hildebrandmachinery.com

Betenbender Manufacturing, Inc......................................27 www.betenbender.com

Boschert Precision Machinery.........................................13 www.boschertusa.com

Carell Corporation.............................................................16 www.carellcorp.com

Cole-Tuve, Inc.......................................................................15

HOUSTEX............................................................................21 www.houstexonline.com

HYDMECH...........................................................................23 www.hydmech.com

Hydra Service......................................................................38 www.hydraservice.net

HyPneuMat inc....................................................................37

www.coletuve.com

www.hypneumat.com

Cosen Saws, USA..............................................................IBC

IMDauctions.com................................................................53

www.cosensaws.com

www.imdauctions.com

Design-2-Part Shows..........................................................52

Industrial Motor Service....................................................39

www.d2p.com

www.industrialmotorservice.com

Dynabrade, Inc....................................................................BC

Infinity Rebuild.....................................................................31

www.dynabrade.com

www.infinityrebuild.com

e-Black Solutions.................................................................26 www.e-blacksolutions.com

Jordan Craig Machinery

www.eaglebendingmachines.com

Eastern Electrical Liquidators...........................................50 www.eastelec .com

Edwards Manufacturing Company.................................IFC www.edwardsironworkers.com

The Electric Barn, Inc.........................................................50 www.electricbarn.com

Essex Structural Steel Co..................................................26

Marvel Manufacturing Company, Inc................................. 9 www.marvelsaws.com

Melmor Associates..............................................................49 www.melmor.com

Northwest Machine Tool Expo........................................26 www.MachineToolExpos.com

Phase-A-Matic......................................................................38 www.phase-a-matic .com

Raco Industrial Corporation............................................43 www.raco.com

Radwell International, Inc................................................. FC www.Radwell.com

RAS Machine Tool Technologies Inc................................32 www.rasmachinetool.com

Repair Parts Inc...................................................................32 www.repair-parts-inc .com

Rockford, Ettco Procunier................................................53 www.rockford-ettco.com

Schweiss Doors...................................................................38 www.schweissdoors.com

SCT........................................................................................25 www.sct-usa.com

Int’l. LLC...............................................................................46 www.jordancraigmachinery.com

Eagle Bending Machines.....................................................16

www.macmhydraulic .com

Kanetec USA Corp.............................................................37 www.kanetec .com

Select Equipment Company..............................................51 www.selectequipment.net

Siemens Industry, Inc............................................................ 5 www.usa.siemens.com/cnc

Kashurba Web Design........................................................16

Speedycut..............................................................................53

www.insustrialwebsites.us

www.speedycut.com

KEC Incorporated..............................................................48

Stor-Loc................................................................................... 7

www.weldingequipment.com

www.storloc .com

Koster Industries, Inc..........................................................49

Tormach................................................................................25

www.kosterindustries.com

www.tormach.com

Kyzen.....................................................................................17

Trim-Lok................................................................................17

www.essexstructuralsteel.com

www.kyzen.com

www.trimlok.com

Federal Knife, Inc.................................................................42

L&L Special Furnace Co., Inc.............................................49

U S Shop Tools.....................................................................11

www.federalknife.com

www.hotfurnace.com

www.usshoptools.com

Formdrill USA Inc...............................................................35

Machinery Network Auctions..........................................53

Ultimate Tube Bender Parts Plus, Inc..............................33

www.formdrill-usa.com

www.machinerynetworkauctions.com

www.benderparts.com

54

| IMD | January 2015 | www.IndMacDig.com

tHe pinnacle of cutting performance Cosen Band saw advantages:

• US availability of parts • Local service • Fast ROI • Model choices & Pricing • User friendly features

productiVity cnc-430 smart cnc control programmable bandsaw

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over 100 models aCross 7 produCt lines

16.9” Round capacity Recommends cut rates and speeds based on material Automatic first cut Blade life management Auto material width sensor

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Visit us at Houstex bootH #229

13” x 20” Capacity Miters up to 60 degrees Automatic Machine Index For Production Sawing or Fabricating

quality bandsaws featured at Houstex 1-877-sawing-1

info@cosensaws.com

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www.IndustrialMachineryDigest.com | January 2015 | Industrial Machinery Digest |

IBC

Presorted Standard U.S. Postage PAID Lebanon Junction, KY Permit # 756 3590-B Hwy 31 South PMB #233 Pelham, AL 35124

Dynabrade_IMD_Dec2014_Layout 1 11/6/14 3:36 PM Page 1 www.IndustrialMachineryDigest.com

Dynabrade’s line of air-powered General Purpose Tools is now available at even lower prices! Choose from any one of these tool lines, which includes a Lifetime Warranty, Free On-Site Demonstrations, Excellent Customer Service and the quality you have always expected. Plus, with our products in stock and ready for immediate delivery, these are just more examples of The Dynabrade Difference!

DIE GRINDERS

DISC SANDERS

GRINDERS

CUT-OFF TOOLS

DRILLS