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IndustrialMachineryDigest.com | July 2026

North America’s Manufacturing Resource for Industry Professionals Since 1986

Built to Last: How the First Combilift C-Series Continues to Deliver Safer Material Handling After 28 Years At J.G. Kelly Supplies in Monaghan, Ireland, the original Combilift C-Series remains in daily operation, proving the long-term value of purpose-built equipment for handling oversized loads safely and efficiently. Inside A Next-Gen Fabrication Workflow Designing Safer Process Control Building Better Inspection Data Closing The Last 30% Cost Control Begins Before The Cut Industrial AI Moves From Pilot To Production The Science Of Tool Holder Concentricity

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Table of Contents

July 2026 8 10 14

FABRICATION

MATERIAL HANDLING

EDITORIAL DIRECTION INDUSTRY NEWS Inside A Next-Gen Fabrication Workflow Built to Last: How the First Combilift C-Series Continues to Deliver Safer Material Handling After 28 Years At J.G. Kelly Supplies in Monaghan, Ireland, the original Combilift C-Series remains in daily operation, proving the longterm value of purpose-built equipment for handling oversized loads safely and efficiently.

SAFETY & MAINTENANCE Designing Safer Process Control Valmet’s UX approach to distributed control system design emphasizes clarity, situational awareness, and faster operator decision-making in safety-critical process environments.

QUALITY Building Better Inspection Data A comparison of manual rounds, fixed sensors, and automated mobile robots shows how inspection strategy affects data quality, consistency, worker exposure, and total cost.

ROBOTICS

METALWORKING

SOFTWARE

Closing The Last 30% Cost Control Begins Before The Cut Industrial AI Moves From Pilot To Production Cisco’s 2026 State of Industrial AI Report for Manufacturing shows manufacturers are investing in AI for productivity and cost reduction, but network readiness, cybersecurity, and IT/ OT alignment will determine whether deployments scale.

TOOLING & WORKHOLDING

47 49 50

SURPLUS BUYING & SELLING

The Science Of Tool Holder Concentricity

CLASSIFIEDS

ADVERTISER INDEX

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This July issue carries special meaning for us. Industrial Machinery Digest is celebrating 40 years of serving the industrial machinery industry — four decades of covering the people, companies, technologies, and ideas that keep manufacturing moving. It is especially fitting that this milestone arrives in the same month the country marks its 250th year. Both anniversaries are reminders that progress is built over time, through persistence, reinvention, and the work of people who know how to make things last. That same spirit is visible across manufacturing today. The industry is in a practical mood. Companies are no longer asking whether automation, AI, robotics, advanced tooling, or connected systems can work. They are asking whether those investments can reduce scrap, improve throughput, protect workers, shorten setup time, strengthen quality, and deliver measurable results on the plant floor. That is an important change. The strongest manufacturers are not chasing technology for its own sake. They are looking for better coordination between people, machines, data, and process. A sensor, robot, inspection tool, or machine control only creates value when it is connected to a workflow that can act on the information it provides. The same is true of cost. Real cost control starts long before the final part is made. Poor planning, unstable processes, inconsistent inspection data, downtime, rework, missing tools, and unclear communication all show up later as lost margin. The manufacturers making progress are looking upstream and asking where those costs are created in the first place. Safety is following a similar path. It is no longer just a matter of compliance or protective equipment. It is also about clearer information, better ergonomics, reduced exposure, cleaner air, smarter interfaces, and systems that help people make the right decision under pressure. What stands out most is that manufacturers do not necessarily need to start over. Many already have capable machines, skilled employees, automation equipment, inspection tools, and years of process knowledge. The opportunity now is to connect those pieces more effectively. That may define the next phase of industry: finishing what has already been started. The companies that lead will be the ones that integrate wisely, invest with purpose, and turn complexity into consistency. After 40 years, we remain proud to tell those stories. That is not hype. That is progress.

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Industry News

INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industry's top companies. WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com

Arnold Magnetic Technologies Expands Thailand Operations Arnold Magnetic Technologies Corporation, a subsidiary of Compass Diversified and a global manufacturer of high-performance magnets, magnetic assemblies, precision thin metals, and electric motors, announced plans to expand manufacturing capabilities at its Amata City Chonburi facility in Thailand. The multi-million-dollar investment will strengthen Arnold’s global manufacturing footprint, reduce risk in the permanent magnet supply chain, and increase capacity for customers across Asia Pacific and Europe. The Thailand facility, which began operations in October 2024, holds ISO 9001 and AS 9100 certifications. Initial production focused on electromagnetic rotor and stator assemblies. The new investment will add samarium cobalt magnet production, shaping, and finishing capabilities, ultimately doubling Arnold’s overall magnet production capacity. Phase I investments, completed in May 2026, established magnet finishing capabilities at the site. Phase II investments have begun and will establish samarium cobalt magnet production, with full operational readiness expected by mid-2027. The added capabilities are also expected to ease capacity constraints and improve lead times at Arnold’s samarium cobalt magnet production facility in Lupfig, Switzerland. For More Information: www.arnoldmagnetics.com

CERATIZIT Adds Technical Sales Engineer For Southeast Region CERATIZIT USA has added Adam Johnson as technical sales engineer for the cutting tool division in the Southeast

region. Johnson will support customers across Alabama, Mississippi, and Tennessee. Johnson brings 20 years of manufacturing experience, including hands-on machining, production leadership, and nine years in cutting tool sales. His background includes supporting process improvements and complex manufacturing environments in automotive and aerospacerelated applications. Based in Anniston, Alabama, Johnson has worked closely with manufacturers throughout Alabama, Mississippi, and Tennessee since 2017. In his new role, he will support customers with CERATIZIT’s cutting tool portfolio, application expertise, and broader commitment to quality, sustainability, and regulatory compliance. CERATIZIT USA is part of the CERATIZIT Group and provides tooling solutions and services for metal cutting industries, including automotive, aerospace, medical, and oil and gas. The company’s vertically integrated tungsten supply network in the United States includes Global Tungsten & Powders, supporting supply chain security and consistent material quality for manufacturers producing critical components. For More Information: www.ceratizit.com

Davi To Host Grand Opening At New North American Headquarters Davi, Inc. will celebrate the grand opening of its new North American headquarters and Davi Academy with a weeklong series of events Sept. 14-18, 2026, in Carrollton, Texas. The event series will begin with a ribbon-cutting ceremony at noon CDT on Monday, Sept. 14. Throughout the week, invited guests will be able to attend live machine demonstrations, explore Davi’s plate 2025 t.com | June chineryDiges IndustrialMa

Since Professionals for Industry Resource ufacturing rica’s Man North Ame

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rolling and automation technologies, and participate in educational sessions and customer training. The week will also include a shipbuilding and defense seminar featuring Davi and several industry partners at noon CDT on Thursday, Sept. 17. The seminar will address the needs of North American manufacturers and fabricators supporting naval and defense applications, including rolling technologies, automation strategies, and production efficiency initiatives. Davi announced in April 2026 that it was moving its North American operations into a larger headquarters designed to serve customers throughout the United States and Canada. The facility provides additional space for customer events, technology demonstrations, training, machine refurbishment, and customer support. The new demonstration area will house nine Davi machines representing the company’s plate and angle rolling product lines. It will also showcase technologies including Davi’s advanced CNCs and AI-Vision in-process laser-measuring system. The facility will stock additional spare and replacement parts, prepackaged maintenance kits, and accessories to help support faster response times and maximize production uptime. For More Information: www.davi.com

Limitless Labs Raises $20M Series A For Precision Manufacturing AI Platform

RS Named One Of North America’s Most Inspiring Workplaces RS has earned a 2026 Top 100 North American Inspiring Workplaces Award, marking the company’s third consecutive year receiving the recognition. RS ranked No. 27 among the 2026 Top 100 North American Inspiring Workplaces, improving by 40 positions from 2025. The Inspiring Workplaces Awards recognize organizations across industries for building cultures rooted in trust, inclusion, wellbeing, and meaningful employee experience. Rankings are based on the input of an independent expert judging panel and cover regional categories including Global, North America, U.K. and Ireland, Europe, Middle East and Africa, Australasia, Asia, and Latin America. RS was first recognized by Inspiring Workplaces in 2022, when it ranked No. 33 in the Top 50 Inspiring Workplaces in North America. In 2024, the company earned both a Top 100 North American Inspiring Workplaces Award and a Top 100 Global Inspiring Workplaces Award. In 2025, RS ranked No. 67 in North America before moving to No. 27 in 2026. RS earned its 2026 ranking based on priorities, initiatives, and achievements in six categories: culture and purpose, leadership, wellbeing, inclusion and belonging, employee voice, and employee experience.

Limitless Labs, formerly LimitlessCNC, announced a $20 million Series A funding round co-led by Dell Technologies Capital and Square Peg, with participation from Grove Ventures, Meron Capital, and Kinetica. The company develops an agentic physical AI platform for CAD/CAM in mechanical manufacturing. Limitless Labs’ platform works inside CAD/CAM systems used by engineers and manufacturers to help capture, standardize, and scale the expertise of experienced CNC programmers. The company said the platform has moved from initial pilots to production deployments with Blue Origin, Cadillac F1, Sandvik, and Iscar across aerospace, defense, motorsports, and industrial machinery applications. The company’s Physical AI Foundation Model is trained on metal cutting physics, CAD geometry, and machine constraints. The model powers Limitless Labs’ CAM Agent, which currently works inside platforms including Mastercam, NX, and Creo. Given a CAD file, the CAM Agent can identify features, recommend tools, sequence operations, generate toolpaths, and help produce shop-floor-ready programs while engineers maintain control of the workflow. The new funding will support the development of a dedicated U.S. commercial organization, continued advancement of the company’s Physical AI Foundation Model toward closed-loop CNC automation, expansion of its CAM Agent, and growth of its deep-tech research lab in Tel Aviv. The company also expects to roughly double headcount over the next 12 months.

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12 | IMD July 2026

Siemens And Ucaneo Partner To Scale Direct Air Capture Technology Siemens and German climate technology company Ucaneo have partnered to scale electrochemical direct air capture technology from industrial pilot to commercial scale. Siemens will serve as Ucaneo’s preferred automation and digitalization partner and will deploy technology from the Siemens Xcelerator portfolio. The companies are developing a standardized automation platform designed to support rapid deployment by Ucaneo and licensed operators worldwide. Ucaneo’s electrochemical direct air capture process removes carbon dioxide from ambient air and delivers high-purity carbon dioxide at more than 99.9 percent purity. Ucaneo’s first-of-a-kind industrial plant in Berlin has a nameplate capacity of 150 metric tons of carbon dioxide per year and is scheduled for commissioning in July 2026. The facility is set to be officially inaugurated July 2, 2026, and is expected to become Germany’s largest direct air capture facility. Siemens is supporting Ucaneo across process automation, instrumentation and analytics, drive technology, and digitalization, with additional process control and simulation technologies planned for future project phases.

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Fabrication

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FABRICATION Transforming Materials Into Excellence Discover the innovative tools and technologies shaping today’s manufacturing landscape. Highlighting processes that transform raw materials into precision-crafted products, from advanced cutting and forming systems to welding and finishing techniques, the focus remains on efficiency, accuracy, and innovation driving modern fabrication. From advancements in automation and sustainable manufacturing practices to the latest developments in material processing, gain insights into trends and solutions that enhance productivity, improve quality, and maintain competitiveness in a rapidly evolving industry. This overview showcases the equipment and expertise behind the products powering industries worldwide.

14 | IMD July 2026

Inside A Next-Gen Fabrication Workflow

iver City Metal Fabrication uses 3D scanning to improve field measurements, reduce rework, and produce accurate replacement components for complex industrial environments. In heavy industry, precision is essential. At facilities such as steel mills and refineries, ductwork systems, chutes, hoppers, feeder bins, and flanges are often modified repeatedly over time through repairs, field cuts, and other on-site changes. As a result, existing equipment may no longer match original drawings. For fabricators tasked with replacing or modifying those components, that mismatch can create costly problems. A part that looks right on paper may not fit when it reaches the jobsite, leading to delays, rework, and additional site visits. River City Metal Fabrication, a family-owned fabrication company based in Baton Rouge, Louisiana, faced that challenge regularly. The company serves commercial and industrial customers, including work inside complex plant

environments where accurate on-site measurements are critical. Candace Forbes, vice president of River City Metal Fabrication, encountered the issue firsthand as she became more involved in leading projects. Many of the company’s jobs involved replacement ductwork or structural metal components inside industrial plants, including a nearby steel mill operated by Nucor. “The ductwork and chutes had been field-cut so many times,” Forbes said. “They were basically botched, and you couldn’t get exact measurements.” Before adopting 3D scanning, the team relied on traditional measurement methods. For simple projects, tape measures, visual checks, and field notes could be sufficient. But for complex equipment with corrosion, irregular modifications, hidden features, or difficult access points, manual measurements were not always reliable. In some cases, parts fabricated in the shop required rework once they were installed on-site.

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

That need for better field data led Forbes to explore 3D scanning.

Finding A Practical Field Measurement Tool Forbes spent nearly a year researching 3D scanning technology. Coming from a fabrication background rather than a digital engineering background, she evaluated the equipment from a practical standpoint. The scanner had to work reliably in demanding industrial environments where conditions are often dusty, hot, crowded, and difficult to access. During her research, Forbes evaluated several handheld scanners, including a system that required targets, a laptop, and a full setup process before scanning could begin. A demonstration at the Nucor site made the challenge clear. The setup took about 45 minutes, which was not practical in a busy industrial facility. River City needed a scanner that was portable, fast, and simple to operate in the field. The company ultimately selected Artec Leo, a fully wireless 3D scanner with onboard processing and a built-in touchscreen. Leo’s tetherless design addressed several of the problems Forbes had identified. The scanner does not require external markers or targets, eliminating the need to place reference stickers in hard-to-reach areas. It stores data internally and runs on battery power, allowing it to be used in the plant without additional equipment or cables.

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Forbes purchased the scanner through Digitize Designs, an Artec 3D Ambassador in the U.S. Working with Bo Helmrich helped River City evaluate the technology and integrate it into the company’s workflow. “I purchased my Artec 3D scanner specifically to support projects for Nucor Steel, the largest steel producer in the country,” Forbes said. “The scanner gives me the ability to detect leaks, wear in materials, capture complex geometries, verify dimensions, and streamline fabrication workflows, ensuring Nucor receives precise, reliable, and efficient service.”

Capturing Existing Conditions On-Site At River City Metal Fabrication, scanning is performed directly at the jobsite. Forbes typically travels to the plant with the Artec Leo to capture the equipment that needs to be replaced or modified. Most projects involve components such as ductwork, chutes, hoppers, feeder bins, and flanges — all of which can be difficult to measure accurately using conventional methods. With Leo, Forbes powers on the scanner and captures an object’s geometry in a process similar to recording a video. Real-time feedback on the scanner’s touchscreen displays scan quality and helps the operator maintain the correct distance from the object. For symmetrical parts, Forbes does not always need to scan the entire object. After capturing one half, she can share the data with River City’s CAD expert, who can unfold it and build the full model. This approach reduces time in the field while still providing the scan data needed for fabrication.

Leo has been used extensively at the Nucor steel mill, where Forbes scans everything from individual flanges to large sections of industrial ducting. On one project, she scanned a chute system spanning nearly 400 feet through six levels of the facility. “I scanned it floor by floor — six levels,” Forbes said. “Then we combined everything together.”

From Scan Data To Fabrication After the field data is captured, Forbes performs initial processing in Artec Studio. The process includes cleaning up scans, aligning them, and generating a mesh. For large projects, such as multi-level chute systems, multiple scan sections can be merged into a complete 3D model. Once processing in Artec Studio is complete, the files are exported and shared with River City’s CAD engineer. For larger datasets, the team may use ShareFile to transfer files from the field to the office. Depending on the project, the workflow can then continue in Geomagic or SOLIDWORKS. Geomagic is typically used for reverse engineering tasks, including converting scan data into usable surfaces and reference geometry. The finalized digital models can then be imported into SOLIDWORKS, where fabricationready designs are created. With accurate scan data guiding the process, River City’s fabrication team can produce components with greater confidence that they will fit correctly when installed.

Improving Accuracy And Turnaround For River City Metal Fabrication, 3D scanning has changed how projects move from field measurement to fabrication. Instead of relying on approximate measurements and repeat site visits, the team can work from precise digital models of existing equipment. The company has used the workflow to produce more than 400 pieces of ductwork with zero measurement errors, according to the case study. The approach has helped reduce rework, improve collaboration between field and CAD teams, and shorten turnaround times on complex fabrication projects. For Forbes, the benefits go beyond efficiency. Working closely with both the field and fabrication sides of the business gives her a clear view of the full project lifecycle — from scanning existing equipment, to designing replacement parts, to fabricating components, to seeing the completed installation.

Customers have noticed the difference as well. “The people at Nucor have been incredible partners,” Forbes said. “They’ve trusted me to bring quality work, and that trust has pushed me to keep raising the bar. Being a woman in this industry can be challenging, but working with teams who recognize ability, not assumptions, makes all the difference.” Under Forbes’ leadership, River City Metal Fabrication

16 | IMD July 2026

shows how modern measurement technology can improve results in demanding industrial environments. By combining fabrication experience with 3D scanning and CAD tools, the company has built a workflow that helps reduce errors, improve fit-up, and support more efficient project execution.

PRIMA POWER

Prima Power Highlights Combination Machines For Flexible Sheet Metal Fabrication

The 3-Dimensional Services Group, a manufacturer of production-intent prototypes and low-volume production, has installed a new 60-kW fiber laser, adding to its lineup of manufacturing technologies. According to Douglas Peterson, founder and CEO, the acquisition continues the company’s investment in major capital equipment and complements its existing laser cutting capabilities. “We have never been more optimistic about the future,” Peterson said. “Our continued growth in the on-demand manufacturing sector, the ever-expanding range of services we offer, and our core mission of providing clients with a complete one-stop manufacturing resource all make these investments essential to keeping our technology at the forefront of the industry.” The G.Weike 60-kW fiber laser is designed for heavy fabrication, steel structures, thick-plate cutting, and high-volume industrial applications. The machine is capable of cutting materials up to 4 inches thick at a 45-degree bevel and offers a 16-by-32-foot cutting area. The new fiber laser joins several other companywide systems, including 3- and 5-axis equipment. The 3-Dimensional Services Group, headquartered in Rochester Hills, Michigan, offers tool design and manufacturing, machining, metal forming, metal bending, laser cutting, plastic injection molding, and assembly services.

Prima Power, a provider of sheet metal working manufacturing solutions, is highlighting its Combi Genius and Combi Sharp punch-laser combination machines, which integrate high-speed punching and fiber laser cutting within a compact footprint. The Combi Genius is designed to support flexibility, productivity, and efficiency for manufacturers. The machine combines a high-capacity turret with IPG fiber laser resonators available in 3-, 4-, or 6-kW configurations. It enables multiple operations, including punching, tapping, forming, marking, and laser cutting, in a single setup. The integration can help reduce production time and optimize floor space by eliminating the need for multiple machines. Both machines deliver high-quality cutting across a range of materials and thicknesses, including aluminum, mild steel, stainless steel, brass, and copper up to 8 mm. This allows manufacturers to adapt to shifting production demands. The modular design supports customization and integration with Prima Power automation solutions, including automated loading and unloading, material handling, part sorting, and storage systems. Supporting up to 400 tools, the Combi Genius reduces downtime and enables complex part production with improved material utilization. Intelligent ram technology, including an optional rotating punching ram, further shortens changeover times. Automation options such as Compact Express, LST/ LSR, and Night Train help streamline part sorting and reduce manual handling, enabling lights-out production and increased throughput. Energy efficiency is built in through servo-electric EcoPunch technology, which delivers up to 82 percent energy savings, low maintenance, and high operational speed. User-friendly software, including the Tulus Suite, simplifies programming, monitoring, and production flow with intuitive interfaces, ERP integration, and real-time analytics. Comprehensive life-cycle support, including process analysis, training, preventive maintenance, and remote care, helps support long-term performance.

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IMD | 17

Material Handling

MATERIAL HANDLING Empowering Efficiency and Precision Material handling is at the heart of efficient industrial operations, focusing on the movement, storage, and organization of materials. This section highlights strategies and technologies that streamline these processes, from automated storage and retrieval systems to advanced conveyor solutions. Readers can explore innovations like forklifts, cranes, hoists, and magnetic lifters, which play a pivotal role in optimizing material flow across warehouses, factories, and supply chains. In addition to hardware advancements, this area emphasizes cutting-edge solutions like warehouse management systems and parts tracking technologies, which integrate seamlessly into modern production environments to enhance operational control. Topics also cover sustainable practices, such as energy-efficient lift equipment and ergonomic tools designed to improve workplace safety while reducing strain. Whether tackling inventory management or enhancing material logistics, this section provides the insights and tools needed to excel in today’s industrial landscape.

18 | IMD July 2026

n material handling, the right piece of equipment can do more than solve an immediate operational challenge. It can reshape workflow, improve safety, reduce labor demands, and deliver measurable value for decades. That has been the experience at J.G. Kelly Supplies in Monaghan, Ireland, where the first-ever Combilift C-Series multidirectional forklift is still in operation 28 years after it was introduced. As National Forklift Safety Day brings renewed attention to safe lift truck operation and risk reduction,

the story of this machine offers a practical reminder for manufacturers, distributors, and warehouse operators: safety often begins with selecting equipment designed for the specific demands of the job. For J.G. Kelly Supplies, the challenge was clear. The company needed to move long PVC stillages measuring up to six metres through a doorway only four metres wide. Conventional counterbalance forklifts were not designed for that type of movement in such a constrained space. The loads were long, the access

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was narrow, and the site layout created operational pressures that affected both productivity and safety. Before adopting the Combilift solution, the company relied on traditional forklift methods that required additional maneuvering and created disruption outside the facility. “Before, we just used to use counterbalance trucks,” said operator Tony McManus. “We had to reverse a lorry in here and were on a main busy road in the town.” That process placed added strain on operators and created potential exposure for pedestrians, vehicles, and workers involved in unloading. It also tied up personnel and increased the time required to move material safely. The introduction of the Combilift C-Series changed that workflow. “But now, it just pulls up in the loading bay,” McManus said. “We can offload it safely, both sides if needed, with minimal obstruction to traffic.”

Solving the Long-Load Challenge The defining advantage of the C-Series is its multidirectional capability. Unlike a standard counterbalance forklift, the machine is designed to travel forwards, backwards, and sideways. That makes it particularly well suited for handling long loads in confined spaces, where conventional lift trucks may require wide turning areas or complicated repositioning. For J.G. Kelly Supplies, that capability allowed operators to move lengthy PVC stillages sideways through restricted access points with greater control and stability. Instead of forcing a standard truck into an application it was not designed to handle, the company adopted a machine engineered specifically for long-load movement. The result was a safer and more efficient process. The C-Series allowed the company to reduce traffic disruption during unloading, shorten unloading times, and limit the amount of manual

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IMD | 19

labor required. It also improved control around oversized material, reducing the risks that can occur when long products are moved through tight environments. “With the C-Series, it’s less labour intensive than it used to be,” McManus said. “It would take a lot of people to offload containers before, but now, one operator can offload a container in a short space of time compared to before.” That shift is significant. In many operations, safety and efficiency are often treated as separate objectives. In practice, they are closely connected. When a lift truck is properly matched to the load, aisle width, doorway clearance, and unloading process, the operator has better visibility, better control, and fewer unnecessary movements to manage. The task becomes faster because it becomes more controlled.

Stability Where It Matters Another important feature of the C-Series is its integrated platform, which supports long loads during transport. For lengthy stillages, this additional support helps improve load stability and gives operators greater confidence when moving material through the facility. “We know that it’s a lot safer,” McManus said. “Once you get the load on the platform, you can sort of relax almost. You’ve got that stability of it being on the rest beds.” That stability has practical value on the shop floor and in the yard. Long loads can behave unpredictably if they are not properly supported. Even small shifts can create hazards for operators and nearby personnel. By allowing the load to rest securely on the machine’s platform, the C-Series helps create a more predictable handling process. For facilities working with pipe, timber, steel, aluminum extrusions, profiles, panels, or other long materials, that kind of stability can be central to both productivity and safety. It reduces the need for workarounds, minimizes unnecessary handling, and helps operators complete movements with fewer interruptions.

A 28-Year Return on Investment While the safety and workflow improvements were immediate, the longevity of the original C-Series has become an equally important part of the story. Nearly three decades after it first entered service, the machine remains in operation at J.G. Kelly Supplies. For Managing Director Paul Kelly, that durability exceeded expectations. “I never expected we’d still be using the same forklift nearly three decades later,” Kelly said. “But it’s a testament to the build quality of the machine as it’s still running after 28 years.” During that time, multiple conventional forklifts have come and gone from the business. The original Combilift, however, continues to perform its role. Its reliability has been supported by robust engineering, regular preventative maintenance, and responsive local service. “It doesn’t really take much maintenance,” McManus said. “We have changed filters or timing belts over the

20 | IMD July 2026

years, but it’s still got the original engine from when it arrived here.” Routine maintenance has included regular checks of oil, coolant, hydraulics, tyres, and greasing. Those basic preventative measures have helped keep the machine reliable and reduced the likelihood of major interruptions. For many industrial operations, downtime is one of the most expensive and disruptive consequences of equipment failure. When a critical lift truck is unavailable, shipping, receiving, production flow, and customer service can all be affected. At J.G. Kelly Supplies, the original C-Series has rarely created that problem. “In 28 years, it’s very rarely had to be taken away for repairs,” McManus said. “Any issues we’ve had have usually been fixed on site, and quickly. That’s the main thing, because if the machine is out of action for any length of time, we’re in trouble.” That reliability underscores an important point for material handling decision-makers. Purchase price is only one part of equipment value. Long-term return on investment also depends on uptime, serviceability, maintenance requirements, operator confidence, and the ability of the machine to continue meeting the needs of the application over time.

Tailored Equipment for Specific Applications The success of the original C-Series also influenced future equipment decisions at J.G. Kelly Supplies. The company later expanded its fleet with additional Combilift products, including a pedestrian Combi-CS and an Aisle Master for its Limerick warehouse. Those additions reflect the company’s continued focus on matching equipment to the application rather than relying on one-size-fits-all solutions. “Combilift are very good at having a look at what you need and then they can tailor the product to suit you,” Kelly said. “We had the height of the mast and weight limit tailored to what we needed in our Combi-CS.”

That ability to tailor equipment can be particularly valuable in facilities with space constraints, unusual load dimensions, changing storage requirements, or site-specific safety concerns. In many operations, the goal is not simply to move material from one point to another. The goal is to move it safely, consistently, and efficiently within the realities of the building, workforce, product mix, and customer demand.

crane girder mounting plates help provide smooth travel characteristics and long service life. Stock wheel sizes include 100 mm, 130 mm, 160 mm, and 200 mm. The end trucks are also available for doublegirder cranes and larger wheel diameters by special order. EMH, Engineered Material Handling, is headquartered in Valley City, Ohio, and designs, sells, and manufactures overhead material handling equipment for loads from 25 pounds to 300 tons.

A Practical Lesson in Safer Handling The continued operation of the first Combilift C-Series at J.G. Kelly Supplies offers a clear lesson for industrial facilities: safer material handling is not achieved through operator training alone. Training is essential, but it must be supported by equipment designed for the work being performed. When long loads are handled with equipment not suited to the task, operators may be forced into difficult maneuvers, limited visibility, excessive repositioning, or added manual intervention. Each workaround increases risk. By contrast, purpose-built equipment can simplify the process and reduce exposure at multiple points in the workflow. Nearly 28 years after it was first manufactured and placed into service, the original C-Series continues to support safer operations, faster unloading, improved load control, and better use of available space. For J.G. Kelly Supplies, it has become more than a forklift. It is a long-term productivity asset and a working example of how the right equipment choice can continue paying dividends for decades. As manufacturers and material handling operations evaluate their own safety practices, the message is straightforward: the safest solution is often the one engineered for the application from the start.

EMH CRANE

HSETC End Trucks Provide Over-the-Top Girder Connection Plate Flexibility EMH Crane’s new HSETC End Trucks provide the same advantages as the company’s standard HSE End Trucks with side-friction connection, while adding a girder connection plate on top of the end truck body. Developed by EMH engineering by popular request, the configuration allows crane builders to select their preferred construction. Additional features include a direct-drive splined shaft wheel connection, hardened steel wheels, rail sweeps and bumpers, 60-minute TEFC motors with Class “F” insulation, and DC-rectified brakes. As with all EMH Crane end trucks, the HSETC End Trucks are VFD-ready. The HSETC End Trucks are designed for reliability and economy. The steel structure of each end truck is a torsion-resistant box girder prepared for connection to the crane girder. Precise machining and exact alignment of the

For More Information: www.emhcranes.com

FAIRLANE PRODUCTS

Industrial Roller Materials Support a Wide Range of Applications Fairlane Products has expanded its lineup of industrial rollers with a variety of material options, including black neoprene, urethane, and white nitrile. The rollers are designed for material handling, assembly, and manufacturing operations where controlled movement and accurate positioning are required. Black neoprene is flame and weather resistant and resists gasoline, oil, ozone, and high temperatures. It has a maximum service temperature of 200°F continuous and 250°F intermittent, with a minimum service temperature of -40°F. Urethane provides high abrasion resistance, strength, load-bearing capacity, elongation, and hardness, while also resisting ozone and oxygen. It has a maximum service temperature of 200°F continuous and 250°F intermittent, with a minimum service temperature of -65°F. White nitrile resists gasoline, oil, alcohol, and abrasion, with a maximum service temperature of 175°F continuous and 225°F intermittent and a minimum service temperature of -60°F. Fairlane Products rollers are available in durometers from 20, similar to stiff foam rubber, to 95, comparable to the hardness of a hockey puck. The company’s roller lineup includes shaft-drive rollers in solid, finned, and DuraSoft styles, with diameters ranging from 1.50 inches to 4.00 inches. Solid rollers provide a smooth surface and firm contact across the full roller face. Finned rollers feature grooves that reduce surface contact and allow dirt, debris, and liquids to pass. DuraSoft rollers have a smooth surface permanently bonded to a steel insert and feature teardrop holes that allow the roller to flex for firm, non-damaging contact. For More Information: www.fairlaneproducts.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 21

Safety & Maintenance

Designing Safer Process Control Safety & Maintenance The Cornerstones of Operational Excellence The Safety & Maintenance section is dedicated to creating safer workplaces and ensuring equipment longevity. Covering everything from cutting-edge machine guarding systems to advanced air filtration and dust collection solutions, this section provides actionable insights into workplace protection and preventative maintenance. Whether you're exploring ergonomic tools to reduce operator strain or electrical systems that enhance reliability, this section focuses on products and practices that prioritize both people and machines. In addition to highlighting safety innovations, this section delves into essential maintenance strategies, including retrofitting, rebuilding, and remanufacturing, ensuring that machinery operates efficiently and reliably over time. Maintenance supplies, facility equipment, and accessories are explored alongside new safety technologies designed to meet evolving compliance standards. Readers will discover how a proactive approach to safety and maintenance not only minimizes risks and downtime but also fosters a culture of care and continuous improvement within industrial settings.

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Valmet’s UX approach to distributed control system design emphasizes clarity, situational awareness, and faster operator decision-making in safety-critical process environments.

n industrial control environments, the user experience, or UX, of a distributed control system directly affects how effectively operators monitor and control industrial processes. It also plays an important role in safety. Poor UX can contribute to misinterpretation of data, delayed responses, alarm fatigue, and operational mistakes. A well-designed UX can support faster decisionmaking, reduce training time, improve operator confidence, and help stabilize plant operations. “Today, UX design is no longer a ‘nice to have’ in safety-critical process industries. Instead, it plays an important role in how operators control the process, improve situational awareness, and make the right decisions under pressure,” said Anna Sydänmaa, business manager at Valmet, a global technology provider serving process industries. According to Valmet UX Manager Nina Flink, user experience should not be mistaken for the user interface. The user interface is part of UX and focuses on visual and interactive elements such as layouts, colors, typography, buttons, and icons. UX

is broader. It centers on the overall experience a user has while interacting with a product. In a DCS environment, UX includes the physical workplace, collaboration, workstations, hardware, tools, and the user interface. It also includes the clarity of process displays, the intuitiveness of navigation, the consistency of symbols and terminology, the responsiveness of the system, and the way information is prioritized and presented during both normal operation and abnormal situations.

Reducing Cognitive Load A well-designed user experience helps operators maintain situational awareness by ensuring critical information is available when it matters most. By reducing unnecessary mental effort, it enables faster, more confident decisions and lowers the chance of mistakes. This approach relies on clear visibility into process conditions, alarms that communicate priority and intent without overwhelming the user, and workflows that mirror real operating practices rather than theoretical models.

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The UX also considers how efficiently operators can carry out everyday tasks such as reviewing trends, acknowledging alarms, adjusting setpoints, and performing diagnostics. It also affects how rapidly operators can understand abnormal conditions and take appropriate action. “Safety in process industries cannot be achieved by focusing on equipment alone,” Sydänmaa said. “True safety depends on how people operate, maintain, and manage processes. It is about ensuring operators have the right information at the right time.”

Designing Around Real Operators At Valmet, UX design is incorporated into the development of its distributed control systems. As part of a ground-up approach to designing its new web-based DCS, DNAe, the Valmet design team placed a strong emphasis on improving the system’s user experience. The urgency was driven in part by the growing need for an interface that is easy to use and intuitive while requiring less operator training, as processors face a significant wave of workforce retirements. Valmet’s Automation Solutions business area maintains a dedicated UX team consisting of more than 10 specialists whose sole focus is user experience. These professionals are UX experts rather than engineers or software developers. As a result, configuration workflows, UI workflows, and on-screen components are defined and governed by the UX team, including how each workflow functions and how it is visually presented. According to Flink, the design is based on understanding how operators, supervisors, managers, and engineers actually do their work, rather than focusing only on piping and instrumentation diagrams. “We start by understanding the bigger picture: how people want to work, what they need, and what the process demands. After that, we move into the details,” Flink said. The user interface is structured around practical operating scenarios and user requirements rather than being driven solely by the process itself. Visual elements such as colors, shapes, and symbols are used consistently throughout the system, with alarm colors strictly limited to true alarm conditions. Critical information is presented to process automation users according to their roles. Intuitive dashboards and clear views of the process and its subprocesses enable users to concentrate on what matters most. Information is prioritized so operators can quickly detect subtle changes and respond without delay, in alignment with their responsibilities and regardless of location. Trends and event information are also available through the same user interface.

Supporting Situational Awareness At its core, a well-designed UX enables operators to achieve situational awareness at a glance, Flink said. Situational awareness describes an operator’s capacity to rapidly understand system conditions, identify what

requires attention, and anticipate upcoming developments. To support this, the interface must present information in a clear and intuitive manner. Operators need to immediately understand the current state of the process, recognize abnormal behavior, and make sound decisions without hunting for information or mentally piecing together essential data. “When situational awareness is strong, operators can respond faster and more accurately, reducing the risk of errors and unsafe conditions,” Flink said. In the case of alarms, maintaining situational awareness requires deprioritizing non-critical information and ensuring that key information is placed where operators can easily see it and act on it. In an industrial control room, thousands of alarms can appear in seconds. Operators may have only a few seconds to find the real issue and take corrective action. In high-risk environments where chemicals and flammable materials are part of daily operations, a well-designed UX can make the difference between a near miss and a major incident. “Plants do not want to be managed blindly by alarms alone. Instead, they require clear situational awareness that provides the proper context to effectively address abnormal conditions when an alarm occurs,” Flink said.

Managing More With Less Noise Operators’ roles have expanded, and one person often

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oversees multiple processes, sites, and pieces of equipment. The solution is not simply to add more displays to control rooms. Without clear structure, data quickly becomes noise, delaying responses and increasing the likelihood of human error. “The human factor is the biggest contributor to operational hazards. Misinterpreting a value or making a small mistake can be enough to trigger a serious incident,” said Valtteri Mustonen, solution manager at Valmet. While most incidents do not make headlines, they do occur in process industries. “Emergency situations develop very quickly,” Mustonen said. “Operators must be able to see immediately what is happening so they can react quickly and in the right way.” Ultimately, safety in process industries is influenced not only by technology and procedures, but by how effectively people are able to perceive, interpret, and act on critical information. A well-designed user experience is central to this outcome. It reinforces situational awareness, limits unnecessary cognitive burden, and steers operators toward appropriate actions when speed and precision are essential. By organizing information in a manner that reflects real operating conditions, effective UX design helps stop errors before they escalate and makes a direct contribution to safer, more reliable process operations.

with customers to identify risks and opportunities across facilities, processes, hazardous material flows, and existing protective measures. Based on those findings, DENIOS develops tailored solutions that may include technology, processes, organizational measures, digital tools, and services designed to keep facilities compliant, cost-effective, and operationally ready. DENIOS then plans, supplies, and implements solutions covering safe storage and handling of hazardous materials, leak-free processes, monitoring solutions, and employee training. Because safety requirements continue after commissioning, the company also supports customer solutions throughout their life cycle with consulting, maintenance, audits, modernization, and continuous improvement. DENIOS US, part of its German parent company, was established 36 years ago and is based in Louisville, Kentucky. The company employs nearly 100 people at its Louisville facility across manufacturing, logistics, engineering, support, sales, marketing, administration, purchasing, and related functions. DENIOS offers handling and storage solutions for hazardous materials in small and bulk quantities and has also created a service department to install equipment such as flood and spill barriers and provide maintenance support. For More Information: www.denios-us.com

For More Information: www.valmet.com

DENIOS

Vision Zero Safety Ecosystem Introduced During 40th Anniversary Celebration As part of its year-long 40th anniversary celebration, DENIOS has introduced “Vision Zero,” a holistic safety concept designed to support a future with zero safety accidents. The initiative builds on four decades of safety work by combining consulting, products, and services into a comprehensive safety ecosystem that addresses technical, cultural, and measurable aspects of workplace safety. Vision Zero provides a four-step roadmap focused on preventing harm to people and the environment. The process begins with analysis, as DENIOS personnel work

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NEDERMAN

Fume Eliminator GoMax Supports Intelligent On-Torch Welding Fume Extraction Nederman is highlighting its Fume Eliminator GoMax, an intelligent welding fume extractor designed for on-torch, robotic, cobot, and manual continuous welding applications. The compact, mobile system is designed to capture welding fumes directly at the source before they spread into workplace air. GoMax can be manually activated or automatically controlled by a welding torch or robot. The system automatically regulates pressure to maintain required airflow and performs automatic filter cleaning when needed. Its mobile design allows it to be relocated throughout a facility, and it can also be mounted on a wall to save floor space. The system is equipped with high-efficiency

nanofiber filter media and offers optional HEPA filtration. It is designed to capture fine fume particles generated when welding materials such as carbon steel, alloys, and stainless steel. Accessories allow users to tailor air management to their facilities, including optional HEPA filtration on the outlet and the ability to connect a hose to exhaust air outdoors instead of recirculating it. GoMax can serve up to two workstations or torches simultaneously. High airflow at high negative pressure supports extraction for confined, temporary, and permanent workstations. Nederman said the system can provide up to 25 percent energy savings compared with other products on the market. “GoMax represents an important advancement in weld fume extraction, providing a user-friendly and cost-effective solution for both automated and manual welding,” said Sara Kozma, strategic product manager at Nederman. “By capturing harmful fumes directly at the source, we can significantly reduce operator exposure during welding.”

on cross-border projects or contractors operating in both countries. The integrated four-point chin strap system meets the CCSC requirement and supports Type II classification. Canadian construction firms preparing for the July 1 deadline can order STUDSON dual-certified Type II safety helmets through the company and through distributors and resellers nationwide. STUDSON’s team is also available to assist with bulk orders, site assessment, and CCSC compliance guidance. For More Information: www.studson.com

For More Information: www.nederman.com

STUDSON

Dual-Certified Type II Safety Helmet Meets CCSC Mandate Ahead of Deadline STUDSON announced that its SHK-1 Full Brim Dual Cert Type II safety helmet is certified under both ANSI/ISEA Z89.1 and CSA Z94.1, providing Canadian construction firms, subcontractors, and site visitors with a compliant head protection option ahead of the Canadian Construction Safety Council’s July 1, 2026, mandate. The CCSC mandate requires all workers, subcontractors, and visitors at member jobsites to wear Type II helmets with integrated four-point chin straps beginning July 1, 2026. The requirement is intended to help keep headgear securely in place during falls or impacts and improve protection against traumatic brain injuries. “We designed our Type II dual certified safety helmets to offer significantly improved head protection for industrial athletes across North America,” said Ryan Barnes, CEO of STUDSON. “The industry has been moving toward greater head and face protection for years, thanks to improved technology and greater awareness about protecting the most important asset: the brain.” The SHK-1 Full Brim Dual Cert helmet meets U.S. and Canadian standards, making it suitable for workers

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IMD | 25

Quality

Building Better Inspection Data QUALITY Ensuring Precision and Performance Quality control and assurance are the backbone of manufacturing, ensuring every product meets rigorous standards for precision, performance, and reliability. This section delves into the tools and technologies that enable manufacturers to uphold the highest quality standards. From advanced coordinate measuring machines (CMM) to vision systems and laser inspection equipment, the spotlight is on innovations that enhance accuracy and efficiency in measurement and inspection. Nondestructive testing (NDT) equipment and positional measuring machines are also featured, allowing manufacturers to evaluate products without damage. Tools such as form measurement gauges, cutting tool inspection systems, and tool condition monitoring devices refine production processes and reduce errors. Whether through shrink-fit technologies or video inspection systems, this section highlights the importance of advanced solutions in maintaining precision, ensuring compliance, and driving continuous improvement in industrial operations.

26 | IMD July 2026

A comparison of manual rounds, fixed sensors, and automated mobile robots shows how inspection strategy affects data quality, consistency, worker exposure, and total cost.

or manufacturers, energy producers, logistics operations, and other industrial organizations, inspections are essential to keeping equipment running, maintaining product quality, and reducing the risk of unplanned downtime. But inspection programs are only as effective as the data they produce. That makes the inspection method itself a quality decision. A program built around inconsistent readings, limited coverage, or hard-to-access measurement points can leave teams reacting to problems after they develop. A stronger approach gives operators and maintenance teams reliable information from the right assets at the right time, allowing them to identify trends, compare conditions, and act before small issues become production problems. Industrial operators typically rely on some combination of three inspection strategies: manual inspections, fixed sensors, and automated robotic inspections. Each has strengths. Each also has limitations. Choosing the right mix requires looking beyond the purchase price of a tool

or system and considering how each method performs in the areas that matter most: data availability, accuracy, consistency, responsiveness, worker safety, and long-term cost.

Matching The Method To The Need Fixed sensors are often the first choice when a facility needs continuous, real-time data from a known point. Once installed, a sensor can monitor the same location around the clock, making it well suited for applications such as vibration monitoring, lubrication condition monitoring, and electrical or hydraulic systems where a specific asset or component must be watched continuously. The limitation is coverage. A fixed sensor provides data only from the point where it is installed. Even large facilities with extensive sensor networks cannot instrument every location, and some assets may be too difficult, costly, or hazardous to equip with permanent monitoring hardware. Fixed sensors also require the infrastructure needed to support them, including connectivity, software, training, and long-term management.

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Manual inspections remain valuable because they are familiar, flexible, and relatively simple to deploy. A trained technician with a handheld thermal camera, acoustic tool, or visual checklist can investigate unusual conditions, return to a location for a second look, and apply experience to changing circumstances. For periodic checks in easy-to-reach areas, manual rounds can still be an efficient and practical option. However, manual inspections are labor intensive and difficult to scale. They also introduce variation. A skilled technician may use a highly accurate handheld device, but small differences in timing, angle, distance, or technique can affect the resulting data. When teams are trying to identify subtle changes over time, those variations can make it harder to separate real asset degradation from noise in the inspection process. Automated robotic inspections are designed to address that gap between fixed and manual approaches. Mobile robots can be trained to follow repeatable routes, capture data from multiple assets, and return to the same positions and angles on each inspection. They do not provide the continuous data stream of a fixed sensor, but they can cover more ground than a fixed monitoring network and perform more frequent rounds than human inspectors.

Data Availability And Coverage Modern inspection programs increasingly depend on broad, clean, repeatable datasets. Maintenance teams want information that can support condition-based monitoring, quality tracking, predictive maintenance, and emerging AI applications. That requires more than isolated readings. It requires data that is captured consistently enough to be trusted. Fixed sensors deliver strong data availability where they are installed. For high-value or high-risk assets that require constant monitoring, this can be essential. But when a problem occurs outside the sensor’s coverage area, teams need another way to investigate. Manual inspections can reach many locations, but the data is only available when a person performs the round. Increasing frequency often means adding labor hours, which can be difficult when experienced maintenance workers are already stretched across multiple responsibilities. Mobile robots offer a different coverage model. A robot equipped with multiple sensors can travel through a facility and collect thermal, acoustic, visual, and other inspection data across a wide range of assets during a single route. Because the route can be repeated, the resulting dataset can become more useful over time. Teams can compare readings from the same location, under similar conditions, across days, weeks, or months.

Consistency Drives Quality For inspection data to support quality and reliability decisions, the information must be captured the same way

Handheld tools support manual inspections, but data collection can vary by technician, timing, and technique. Image source: Boston Dynamics.

every time. Inconsistent data can hide early warning signs, create false alarms, or send technicians toward problems that do not actually exist. Fixed sensors are strong in this area. Once installed, they capture data from the same point under similar conditions every day. For applications where the monitoring point is clear and the asset condition can be judged from that location, fixed sensors provide a high level of consistency. Manual inspections are inherently more variable. Even with a defined route and trained technicians, each inspection can differ slightly. One worker may stand at a different angle, INDUSTRIAL MACHINERY DIGEST.COM

IMD | 27

take a reading at a different distance, or capture the image at a slightly different moment in the equipment cycle. Those differences may seem small, but they can matter when teams are looking for gradual changes. Automated mobile robots combine repeatability with reach. By returning to the same point and capturing data from the same position and angle, they can reduce the variation associated with manual rounds while retaining the ability to move through a facility. For quality teams, that repeatability can improve confidence in the data and make trend analysis more meaningful.

Flexibility When Conditions Change Inspection needs rarely stay fixed. A maintenance team may need to investigate a new noise, a thermal anomaly, a process change, or a recently installed piece of equipment. The inspection strategy must be able to respond. Fixed sensors are powerful within their defined monitoring zones, but they cannot easily move to follow a new issue. Expanding coverage usually requires adding more hardware, performing installation work, and ensuring the network can support the additional data. Manual inspections are highly responsive because a technician can return to the field and inspect a new area. That flexibility is one reason manual expertise remains important. The drawback is that it still requires a person to enter the environment, perform the inspection, and document the results. Robotic inspections can supplement automated missions with manual-control operation when conditions change. If a team notices an abnormal reading, a robot can be rerouted to gather additional data or inspect a location that may be unsafe, difficult, or time-consuming for a person to access. This flexibility can help organizations expand inspection coverage without sending workers into every situation by default.

Reducing Worker Exposure Many inspection routes pass through areas that are inherently risky. Technicians may need to work near active machinery, hot equipment, elevated platforms, confined spaces, electrical systems, or locations where leaks and other hazards are possible. Thermal inspections, acoustic imaging, and visual checks may be routine, but the environments where they occur are not always routine. Fixed sensors reduce worker exposure after installation because people do not need to visit the asset as often. Still, workers must install and maintain the sensors, and they may still need to conduct follow-up inspections when a problem occurs outside the monitored area. Manual inspections present the highest recurring exposure because they place technicians directly in the inspection environment. They also consume time that could otherwise be spent on higher-value work such as diagnostics, repairs, analysis, or process improvement. Mobile robots can reduce the need for routine manual rounds in hazardous or hard-to-reach areas. Legged

28 | IMD July 2026

Fixed sensors can provide continuous data from defined monitoring points. Image source: Boston Dynamics.

robots can navigate industrial environments, gather data, and return to charging cycles with limited intervention after routes are established. In this role, automation is not simply a substitute for labor. It can shift skilled workers away from repetitive data collection and toward interpreting results and solving problems.

Understanding Total Cost Cost comparisons can be misleading when they focus only on upfront investment. Manual inspections may appear inexpensive because handheld tools are relatively affordable, but recurring labor costs rise quickly as inspection routes become more frequent or more complex. Scaling manual inspection generally means adding people or taking time away from other maintenance work. Fixed sensors involve more initial planning and infrastructure. The cost includes hardware, installation, software, connectivity, training, and management. In many cases, cost rises directly with the number of points a facility wants to monitor. Automated robotic inspections require upfront investment, planning, route training, and integration into existing workflows. Over time, however, a robot carrying multiple sensors can collect data from many assets without requiring a dedicated fixed sensor at each location or repeated manual rounds by technicians. Better data consistency and increased inspection frequency can also help teams identify issues earlier, reducing the risk and cost of unplanned downtime.

Choosing A Hybrid Strategy The strongest inspection strategy is often not a choice between manual, fixed, or automated methods. It is a hybrid approach that applies each method where it performs best.

A facility might use fixed sensors for assets that require continuous monitoring, manual inspections for periodic checks in accessible areas, and mobile robots for repeatable routes across large, hazardous, or hard-toinstrument environments. In that model, each method supports the others. Fixed sensors provide constant data from critical points. Human inspectors contribute judgment and flexibility. Mobile robots expand consistent coverage and reduce exposure during routine rounds. For quality and reliability teams, the goal is not simply to collect more data. The goal is to collect data that is available, accurate, repeatable, and useful. By evaluating inspection methods through that lens, industrial organizations can build programs that improve uptime, support safer operations, and give teams the confidence to act on the information they collect. For More Information: www.bostondynamics.com

FARO CREAFORM

Laser Line Probe Update Reduces Time to Data on Challenging Surfaces FARO CREAFORM, a business of AMETEK, Inc., has announced an update for its Laser Line Probe portfolio used with the Quantum X FaroArm Series and Quantum Max FaroArm Series. The update introduces refined image-processing algorithms designed to improve scan consistency and reduce time to data, particularly when working with parts that feature difficult and contrasting surface finishes. Laser Line Probes are used in manufacturing for non-contact inspection, reverse engineering, and CAD comparison. They are often applied to dark, shiny, reflective, or highly contrasting surfaces that may require additional setup, multiple passes, or manual adjustment to achieve usable results. The update is designed to help users obtain cleaner, more consistent point clouds with less effort. Powered by DTEX, FARO CREAFORM’s approved LLP processing pipeline, the update focuses on improving results for challenging materials while reducing the need to fine-tune acquisition parameters. Internal performance benchmarks associated with the release indicate improvements of up to 60 percent in time to data on representative challenging parts without compromising measurement integrity. The update also supports workflows using FARO 8-Axis Max, a metrology-grade rotary worktable designed to extend the effective reach of FaroArm-based measurement systems. When used with the Quantum X FaroArm and Laser Line Probes powered by DTEX, the 8-Axis Max measures part rotation through integrated encoders and combines synchronized data from the arm to support a smooth coordinate measurement workflow across larger or more complex parts.

The update applies across the Laser Line Probe portfolio, including FAROBlu xR for high-resolution scans, FAROBlu xS for efficient scan times, and FAROBlu xP for a balance of resolution and efficiency. The release is designed to enhance existing FaroArm and LLP workflows without requiring new hardware. For More Information: www.faro.com

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IMD | 29

robotics

Closing The Last 30% ROBOTICS Driving Automation and Innovation Robotics and automation are transforming modern manufacturing, redefining efficiency, precision, and versatility across industrial processes. From welding robots and robotic tooling to autonomous technology and cobots (collaborative robots), innovations are seamlessly integrating robotics into diverse manufacturing workflows. Key advancements include automated cells and press transfer robotics, enabling streamlined operations and reduced cycle times. Solutions like material handling systems and end effectors highlight the adaptability of robotics in tasks ranging from machining to assembly. With a focus on enhancing safety and productivity, the integration of RFID and enclosure systems, along with comprehensive training, empowers manufacturers to harness the full potential of robotics in an increasingly automated world.

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Intel’s Ricky Watts says the next phase of industrial AI and robotics is less about adding technology and more about integrating the systems manufacturers already have.

ver the past decade, artificial intelligence and robotics have moved from the edge of possibility to the center of manufacturing strategy. What began as isolated pilots, proofof-concept demonstrations, and early experimentation has matured into a more practical question for manufacturers: how can these technologies deliver measurable value on the plant floor? For Ricky Watts, general manager and senior director of Intel’s Industrial and Robotics Division, that shift marks a critical turning point. With more than 30 years of global experience across industrial systems, telecommunications, embedded technologies, control automation, energy, medical devices, transportation, and edge infrastructure, Watts has seen manufacturing technology evolve through multiple waves of transformation. Today, he believes the industry is entering a new phase — one defined less by technology acquisition and more by integration, coordination, and operational outcomes. “The first wave was about

Ricky Watts

possibility,” Watts said, describing a period when manufacturers were largely focused on vision pilots and AI proofs of concept to understand what the technology could do. “The second wave, which is where most serious manufacturers are now, is about outcomes.”

From Possibility To Outcomes That distinction is important. For years, the dominant question around AI and automation was whether a specific use case could work. Could a vision system detect defects? Could a robot operate safely near people? Could an AI model analyze production

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data? Could edge computing bring intelligence closer to machinery and control systems? For many manufacturers, those questions have largely been answered. The new questions are more demanding: What does this deliver? What does it cost? How does it scale? How does it change the structure of operations? How does it connect to systems already in place? According to Watts, that shift changes everything. It affects how manufacturers evaluate vendors, how they structure projects, how they measure success, and how they build internal teams. Companies moving fastest are no longer treating AI as a standalone technology initiative. They are treating it as an operational transformation. That difference can determine whether a project becomes a useful tool or an expensive experiment.

Connecting Awareness To Action Watts describes today’s industrial automation environment through four essential layers: awareness, understanding, decision, and action. Awareness begins with the sensors, cameras, and connected devices that tell a manufacturer what is happening in real time. Understanding comes from AI models that interpret those signals and convert raw data into usable intelligence. Decision is handled by control systems that determine the appropriate response. Action is carried out by robotics, automation equipment, and other

systems that execute the task. In many facilities, these individual capabilities already exist. Manufacturers have cameras on lines, sensors on equipment, robots in cells, software platforms collecting data, and AI models operating somewhere within the business. The challenge is not necessarily that any one layer is missing. The challenge is that the layers often operate separately. “Most manufacturers today have real capability at each layer,” Watts said. “What’s missing is vertical integration — the ability to move from awareness to action in real time, reliably, at production scale.” That is the gap manufacturers must close if they want AI and robotics to become part of the operational fabric of the business. When awareness, understanding, decision, and action are connected, the system no longer behaves like a collection of individual technologies. It begins to function as a single operational intelligence.

The Last 30 Percent This is where Watts sees the greatest opportunity for manufacturers seeking a faster return on automation investments. In his view, many companies do not need to start over or continue buying disconnected tools. They need to finish what they have already started. “Most manufacturers I talk to have roughly seventy percent of what they need,” he said. “They have the

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sensors, the robots, AI models running somewhere in the business, maybe even a data platform. But the last thirty percent — the integration, the real-time data flows, the system-level coordination — is where they’re stuck.” That “last thirty percent” has become one of the most important barriers to ROI in modern manufacturing. A robot that cannot act on real-time intelligence remains limited. A vision system that identifies a problem but does not trigger a response becomes an alerting tool rather than a corrective system. A data platform that collects information but is not connected to the right decision points may improve visibility without improving output. For Watts, the answer is not more technology for technology’s sake. It is a more deliberate focus on integration. Manufacturers must connect systems in ways that support the business outcome they are trying to change. That may mean reducing downtime, improving quality, increasing throughput, addressing labor constraints, or enabling greater flexibility across production lines. Whatever the objective, the technology must be connected to the operational process that can act on the insight.

Technology Deployment Is Not Transformation This lesson has shaped Watts’ own approach over the course of his career. Early on, he believed the hardest part of industrial innovation was the technology itself. Over time, he came to see that the greater challenge is getting people, systems, and processes to move together. “I’ve spent years watching brilliant engineers deploy incredible technology that never delivered its full potential — not because the tech failed, but because it wasn’t connected to anything that could act on it,” he said. That observation reflects a broader reality in manufacturing. Technology deployment and operational transformation are not the same thing. Installing AI, robots, sensors, and software does not automatically produce measurable improvement. Those tools must be tied to workflows, business priorities, production constraints, maintenance practices, workforce capabilities, and decision-making structures. Watts said the most effective approach is to start with the outcome and work backward. Instead of asking what technology can be deployed, manufacturers should ask what operational result needs to change. From there, they can determine what integration is required, what data must move in real time, which systems need to coordinate, and where automation can take action. That outcome-first mindset is particularly important as manufacturers face continued pressure to improve productivity, manage skilled labor constraints, increase resilience, and compete globally. AI and robotics can support those goals, but only when they are deployed as part of a coordinated operating model.

Building On Existing Infrastructure Intel’s role, according to Watts, is to help manufacturers

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build on the infrastructure they already have. Many industrial companies are already running Intel-based systems somewhere within their operations. That existing footprint can become a foundation for moving AI closer to the factory floor and connecting intelligence more directly to production systems. “What I love about what Intel brings to those conversations is that we can tell them honestly: you don’t need to start over,” Watts said. “Most of them are already running on Intel infrastructure, which means we can help them build on what they have, move AI closer to operations, and close that last 30% without disrupting what’s already working.” That is a practical message for manufacturers that have already invested heavily in automation. The path forward does not always require wholesale replacement. In many cases, it requires better coordination between assets, software, edge infrastructure, and control environments. For manufacturers frustrated that AI and automation investments have not yet produced the results they expected, Watts sees opportunity rather than failure. The presence of existing technology means the foundation is there. The work now is to connect that foundation to action. “When we help them close that integration gap, the outcomes they’ve been chasing for years start to materialize quickly,” he said. “That’s what drives me. Not selling technology, but helping operations actually work the way they were designed to.”

Finishing What Manufacturers Started That perspective is especially relevant as the next decade of industrial innovation takes shape. Manufacturers are not lacking interest in AI. Nor are they lacking robotics, sensors, or automation equipment. The limiting factor is often coordination. Watts’ advice to industry leaders is direct: manufacturing does not have an AI shortage. It has a coordination challenge. Most manufacturers, he argues, are already much closer to the future than they may realize. The sensors are on the floor. The automation is in place. AI is already being tested or deployed somewhere in the business. What remains is the hard, practical work of connecting awareness to understanding, understanding to decision, and decision to action. “You don’t need to start over,” Watts said. “You need to finish what you started.” For manufacturers, that may be the defining message of the next phase of smart manufacturing. The winners will not necessarily be the organizations that buy the most technology. They will be the ones that integrate it most effectively, align it with operational outcomes, and build systems capable of acting intelligently in real time. As AI and robotics continue to advance, the competitive advantage will increasingly belong to companies that close the gap between insight and

execution. In that environment, the last thirty percent may prove to be the most important part of the journey. Source: Association for Advancing Automation.

ABB ROBOTICS

Human-Generated Data Advances Robotic Dexterity ABB Robotics is collaborating with California bionics company PSYONIC to advance robotic gripping and dexterity using real-world manipulation data from human prosthetic use. The collaboration combines PSYONIC’s Ability Hand with an ABB GoFa cobot to explore how touch and motion data generated by human prosthetic use can help train robots to perform delicate, variable tasks that have traditionally been difficult to automate. “Human dexterity and the instinctive understanding of how to handle different objects is one of the most difficult things to replicate in industrial-grade robotics, but it’s a fundamental need for truly autonomous and versatile robots,” said Marc Segura, president of ABB Robotics. “As we develop the next generation physical AI, robots will learn and understand the world as we do. This collaboration with PSYONIC will help to close the long-standing gap between human and robot dexterity, opening up new possibilities for a wide range of industries.” Grasping and dexterity are central to ABB Robotics’ vision for Autonomous Versatile Robotics, which focuses on robots that can sense, reason, move, and handle objects with precision in dynamic environments. The collaboration will explore applications across industries including automotive, aerospace, packaging and logistics, and life sciences.

Originally developed for prosthetic use, the PSYONIC Ability Hand combines myoelectric control, touch sensing, and compliant mechanics in a lightweight, multiarticulating design. Its pressure sensors and vibration feedback system enable users to detect contact, grip force, and release, while flexible fingers conform naturally to irregular and deformable objects. “Dexterous manipulation is ultimately a data challenge as much as a hardware challenge,” said Dr. Aadeel Akhtar, founder and CEO of PSYONIC. “By using the same Ability Hand on people and on robots, we can capture high-fidelity real-world data on movement, contact and grip force, then use that to train robotic systems more effectively.” ABB Robotics’ GoFa provides the accuracy and repeatability required for industrial-grade deployment, helping researchers evaluate subtle variations in grip force, finger positioning, and movement. The collaboration will assess how the combined capability can support industrial use cases where traditional gripping technologies struggle with variability, fragility, or complexity, such as handling irregular or delicate objects. For More Information: www.abb.com

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Metalworking

METALWORKING Precision and Craftsmanship in Manufacturing Metalworking encompasses the tools, technologies, and processes that drive precision manufacturing. This area highlights advancements in machining, grinding, lathing, and cutting systems, along with innovations like EDM (Electronic Discharge Machining). It captures the synergy between precision equipment and skilled craftsmanship, essential for producing high-quality components across diverse industries. Focusing on the integration of controls, machining tools, and accessories, metalworking emphasizes the efficiency and accuracy demanded by modern manufacturing. From contract manufacturing to heat treating and gear machinery, it reflects the essential techniques and equipment shaping today’s industrial landscape. Whether utilizing traditional methods or cutting-edge innovations, metalworking celebrates the pursuit of excellence in every detail.

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Cost Control Begins Before The Cut Sandvik Coromant outlines five ways manufacturers can reduce cost at the source by looking beyond tool price and focusing on data, logistics, automation, process stability, and production planning.

n metalworking, the most visible costs are often not the costs that matter most. Scrap, rework, machine downtime, delayed deliveries, inventory problems, and unstable machining processes usually appear late in the manufacturing value chain. But the decisions that create those costs are frequently made much earlier, during design, process planning, operations planning, and production preparation. That is the central message behind Sandvik Coromant’s cost-efficiency framework. Instead of treating cost reduction as a purchasing exercise, the company encourages manufacturers to look at the full path a component takes from design to verification. The goal is not simply to spend less on individual items. It is to build a manufacturing process that produces good parts on time, with fewer unnecessary steps, fewer interruptions, and better use of available resources. The manufacturing value chain includes design, process planning,

operations planning, production logistics, machining, and verification. Each stage influences the next. A component that is difficult to manufacture can add cost long before the first setup. A weak process plan can create bottlenecks. Poor tool availability can stop production. Unstable machining can lead to scrap, rework, and missed delivery targets. For manufacturers trying to improve profitability, the challenge is to identify where cost is created, not just where it appears.

Cost Analysis Comes First The first step is a clear view of the cost situation. Developing a cost-effective manufacturing process without sacrificing quality requires more than knowing the purchase price of tools, materials, or equipment. It requires understanding the cost drivers across the full process. Total manufacturing cost includes direct material, labor, and overhead. Those categories may sound straightforward, but the real picture is

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

often more complex. Tooling, inventory, scrap, downtime, rework, buildings, administration, labor, machinery, and workpiece material all affect the final cost of a component. A decision that reduces one line item can increase several others. This is where many cost-reduction efforts become too narrow. Cutting tool cost is one example. In a typical workshop, Sandvik Coromant notes that cutting tools represent only about 3 to 5 percent of total costs. Reducing tool cost by 30 percent may therefore reduce total component cost by only about 1 percent. If that lower-cost tool also shortens tool life, increases tool breakage, reduces metal removal rates, or creates more scrap, the apparent savings can disappear quickly. A more productive approach is to evaluate how tooling, machining methods, process stability, and output affect the total cost picture. A higher-performing tool may cost more upfront but reduce total cost by supporting longer life, faster machining, fewer tool changes, less scrap, and more predictable production. Cost analysis should not be a one-time exercise. It should be part of continuous improvement. A manufacturer that regularly reviews where cost is created has a better chance of removing unnecessary steps, correcting process weaknesses, and improving profitability without compromising quality.

Make Production Flow Visible Transparency is the next cost lever. Many workshops still rely on manual data collection, disconnected records, and operator experience to understand what is happening on the shop floor. That makes it difficult to plan capacity, identify waste, or compare performance across machines and processes. Connected machines and data-driven production systems make the flow more visible. With the right factory network and machine-monitoring tools, manufacturers can gather feedback around the clock and use that information to improve planning, reduce downtime, and support more efficient operations. A transparent production flow can help manufacturers increase overall efficiency, improve capacity planning, optimize operations within and between facilities, collect operator feedback, and reduce waste and energy consumption. Data is also becoming an important part of sustainability efforts. Without facilitywide visibility into energy use, manufacturers have limited ability to reduce consumption or verify progress. Sandvik Coromant points to its production unit in Gimo, Sweden, as an example of data used throughout the production process. The facility implemented what the company calls a digital thread, connecting automated design, production preparation, production, and feedback from production systems. The operation collects more than 800 million data points per day and has reported a 55 percent increase in pieces produced per person, a 68 percent reduction in batch size, and an 89 percent reduction in throughput time.

The larger lesson is that visibility creates options. When manufacturers know where time, energy, materials, and capacity are being used, they can act on facts instead of assumptions.

Tool Logistics As A Cost Lever Tooling inventory is another area where hidden cost accumulates. A typical workshop may have too much inventory in some places and not enough in others. Tools may become obsolete, sit unused, or be stored near machines instead of in controlled inventory systems. At the same time, operators may lose time searching for tools, spare parts, or equipment. Those delays affect productivity and make it harder to measure tool performance. They can also increase order-processing costs and force companies to carry more inventory than necessary. According to Sandvik Coromant, approximately 80 percent of work is performed with only 20 percent of the tooling. The company also notes that 30 to 60 percent of tools may not be stored properly but instead piled up by machines, while 20 to 30 percent extra time can be spent administrating orders caused by delays from not having the right tools available. Rationalizing the tooling inventory can free capital, reduce tool spend, and improve production flow. A smart logistics solution organizes and manages tools, tracks INDUSTRIAL MACHINERY DIGEST.COM

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consumption, reports cost, and gives managers better insight into stock levels and tool usage. Efficient tool logistics are especially important in mixed production environments, where the right balance between flexibility and inventory control can be difficult to maintain. Modular tooling systems can help manufacturers build optimized assemblies from a limited inventory. Versatile tools that can perform several operations or work across multiple materials can also reduce complexity. Tool management should also consider sustainability. Reuse, repair, refurbishment, regrinding, and recycling can extend tool life and reduce waste. The best outcome is not simply having more tools available. It is having the right tools available at the right time, with the data needed to use them effectively.

Automation With Process Security Automation is often discussed in terms of productivity, but its cost impact is broader. Many programming, tool selection, and setup tasks are still performed manually. Some shops continue to rely on paper catalogs, manual data entry, and judgment based on experience. Skilled workers may have the knowledge needed to make those decisions, but repetitive manual tasks consume time and introduce the possibility of error. Automation can reduce repetitive work, support unmanned production, improve workplace safety, and strengthen process security. It can also reduce the risk of costly mistakes. Something as simple as an incorrect number in machining input can cause machine problems, part errors, or equipment damage. However, automation alone is not enough. To support reliable unmanned or lightly attended production, automation must be combined with high-performing and dependable cutting tools. A shop cannot confidently leave a machine unattended if the machining process is unstable or if tool performance is unpredictable.

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There are several paths toward automation. Design and planning automation can use digital solutions to support CAD/CAM processes. Connected workshops and automated machine monitoring can give real-time visibility into equipment utilization and process behavior. Data-driven machining can connect machine tools and cutting tools so decisions and actions are based on live production information. The benefit is not only that the machine can run with less intervention. It is that employees can spend less time on repetitive tasks and more time on higher-value work such as process improvement, troubleshooting, planning, and engineering.

Stability At The Machine The machining process is where many earlier decisions are proven right or wrong. Stable and efficient machining depends on smart planning, machine utilization, machining efficiency, and short lead times for steps before and after cutting. Idle machine time has a direct effect on profitability. Tool changes, setups, workpiece changes, unplanned stops, tool breakage, bottleneck operations, and other interruptions reduce the amount of time a machine is creating value. Improving metal cutting efficiency, increasing cutting data, and reducing non-machining time can all increase output from the same equipment base. Sandvik Coromant’s framework highlights how little of a typical workday may actually be spent in cut. In a workshop using two shifts, only 24 percent of a 24-hour day, or about 5.8 hours, may be spent on time in cut. Production time may represent 60 percent of the day, with 40 percent being non-production time. Within production time, machining time and non-machining time may be split evenly. Within machining time, metal cutting may represent 80 percent, with the balance consumed by tool changes, spindle movement, and related activity.

That breakdown shows why focusing only on tool price misses the larger opportunity. Shortening setup time, reducing unplanned stops, improving workpiece changeovers, using quick-change tooling, and increasing process predictability can produce larger gains than small reductions in purchase cost. Stable machining also depends on the right methods, strategies, and tool assemblies. Manufacturers can improve performance by optimizing tool assemblies for stability and metal removal rate, applying quick-change tooling to reduce non-machining time, using digital software to shorten CAM programming and tool preparation, monitoring downtime causes, and choosing workpiece materials that support consistent chip control, tool life, and surface quality. In one customer example cited by Sandvik Coromant, changing the tooling and method solution for a first workstation increased productivity by 82 percent, decreased machine time by 47 percent, and reduced production costs by 37 percent. The result was a more balanced production line without the first workstation acting as a bottleneck.

A component can become expensive because it is difficult to manufacture, because the process plan is weak, because the right tools are not available, because data is disconnected, because too many tasks are manual, or because machining is unstable. Those problems may appear as scrap, rework, downtime, inventory cost, or missed delivery. But they often start earlier. For metalworking operations, reducing cost at the source means asking better questions. Is the component designed for manufacturability? Is the right process selected? Are manual tasks being automated where practical? Is the tool inventory controlled? Are machining processes optimized for cycle time, stability, and quality? Is verification preventing rework rather than simply catching problems at the end? When manufacturers can answer those questions with reliable data and act across the full value chain, cost reduction becomes more than a purchasing target. It becomes a system for improving output, quality, sustainability, and profitability at the same time. For More Information: sandvik.coromant.com

Match Priorities To Production Type There is no single cost-reduction plan that fits every metalworking operation. Priorities depend heavily on production type. For mass production, the critical steps are production logistics and machining. The emphasis is on having tools and other production resources available at the right time and maintaining a secure machining process with minimal unplanned stops. For complex components, the critical steps are operations planning, machining, and verification. The focus is on selecting optimized machining methods, protecting high-value workpieces, simulating and verifying toolpaths, and producing the required quality with minimal risk of scrap. For small batch sizes, process planning and operations planning become especially important. Shops need to create accurate quotations quickly, move from programming to machine setup efficiently, and avoid start-up problems when cutting begins. For mixed, recurring components, process planning and operations planning are also critical. The opportunity lies in continuous improvement, so each returning batch is produced more effectively than the last. Understanding production type helps manufacturers avoid generic improvement plans. It directs attention toward the parts of the value chain that have the greatest impact on cost, quality, and delivery.

A More Complete View Of Cost Cost-efficient manufacturing is not achieved by pressuring every supplier for a lower price or reducing every individual line item. It is achieved by understanding how decisions interact across the full process.

ALMCO

PW12 Inline Parts Washing System to Be Featured at IMTS 2026 ALMCO will showcase its PW12 multi-stage inline parts washing system in booth 338009 at IMTS 2026. The system is designed for efficient, high-volume parts washing with continuous wash, rinse, and blow-off operations. Built on ALMCO’s experience with conveyor washer systems, the PW12 will be featured as part of an integrated parts washing and finishing line at the company’s booth. The inline design eliminates repeated part lifting, staging, and transfer steps, helping reduce cycle times and improve throughput. The continuous flow of parts between operations also helps reduce bottlenecks and lower the physical demands on operators, reducing the risk of ergonomic injuries. The PW12 can be custom-designed for each application, with conveyor widths and belt styles configured to move parts directly onto the customer’s preferred material-handling solution without manual labor. Standard features include a variable-speed stainlesssteel conveyance system, removable stainless-steel chip tray, adjustable spray nozzles for 360-degree coverage, and heated wash and rinse tanks. Optional rust inhibitor and drying sections are also available. For More Information: www.almco.com INDUSTRIAL MACHINERY DIGEST.COM

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Software

SOFTWARE The Digital Backbone of Modern Manufacturing In an era where innovation drives productivity, the Software section explores the cutting-edge tools empowering manufacturers to streamline operations, enhance precision, and optimize performance. From CAD/CAM/CAE design platforms to CNC simulation and process verification, this category reveals how digital solutions are revolutionizing the way products are conceptualized, created, and delivered. Covering a broad spectrum of applications—such as ERP systems, factory floor software, and industrial IT—this section emphasizes the importance of connectivity and real-time data in achieving operational excellence. Topics like quality control, job tracking, and program optimization showcase how software bridges the gap between vision and execution, enabling manufacturers to stay competitive in a fast-evolving industry.

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Industrial AI Moves From Pilot To Production Cisco’s 2026 State of Industrial AI Report for Manufacturing shows manufacturers are investing in AI for productivity and cost reduction, but network readiness, cybersecurity, and IT/OT alignment will determine whether deployments scale.

rtificial intelligence is no longer sitting at the edge of manufacturing strategy. For many manufacturers, it has moved into active deployment, tied to production, quality, logistics, energy management, worker safety, and cybersecurity. That shift is the central theme of Cisco’s 2026 State of Industrial AI Report for Manufacturing, developed in association with Sapio Research. The manufacturing-specific report reflects input from more than 350 manufacturing decision-makers across 19 countries at companies with annual revenues above $100 million. The broader research effort gathered perspectives from 1,000 operational leaders across 19 countries and 21 industries. The report points to a manufacturing sector that is past the basic question of whether AI can work in industrial environments. The new question is whether organizations can scale AI securely, repeatedly, and profitably across live operations.

According to the report, 59 percent of manufacturers are actively deploying AI at scale. That does not mean every manufacturer has reached full maturity, but it does show that AI adoption is no longer limited to isolated pilots or research projects. The technology is moving into production environments where it is expected to deliver measurable operational outcomes. The opportunity is significant. The report cites external market research projecting the global AI in manufacturing market to rise from $34.18 billion in 2025 to $155.04 billion by 2030. For manufacturers, that growth is being driven less by novelty and more by the need to improve production workflows, strengthen real-time decision-making, and support predictive maintenance.

Operational Results Drive Adoption Manufacturers are not adopting AI simply because it is new. They

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

are adopting it because they expect it to solve familiar operational problems. Improving productivity is the leading driver behind manufacturers’ interest in AI, cited by 63 percent of respondents. Cost reduction follows at 48 percent, while 34 percent cite improving security and 33 percent point to gaining competitive advantage. Other drivers include improving sustainability, reducing downtime, enhancing worker safety, and meeting regulatory requirements. This creates a practical starting point for AI deployment. Manufacturers are looking for gains they can see in the plant, warehouse, supply chain, or maintenance program. Early outcomes are expected to come from efficiency, responsiveness, and better operational control. The use cases reflect that focus. Process automation leads the list, with 66 percent of manufacturers currently exploring or deploying it. Supply chain and logistics optimization follows at 63 percent, and automated quality inspection ranks third at 54 percent. Energy optimization and sustainability, predictive maintenance, worker safety monitoring, and robotics also appear among the leading use cases. Together, these priorities show how AI adoption is evolving. The earliest applications are tied to productivity and throughput, but the report suggests that more mature adopters are moving toward resilience-focused applications. As AI programs mature, manufacturers place greater emphasis on safety, sustainability, risk reduction, and long-term operational robustness.

High Expectations For ROI The report also shows that manufacturers expect AI to produce results quickly. Eighty-five percent of respondents expect returns within two years or are already seeing outcomes. Nineteen percent are already seeing results, 28 percent expect outcomes within one year, and 38 percent expect them within two years. That short timeframe matters. It indicates that AI is being treated as a near-term operational lever rather than a long-range experiment. Manufacturers are under pressure to move from deployment to measurable impact. The outcomes they want are direct: 58 percent want increased productivity, 49 percent want cost reduction, 35 percent want competitive advantage or innovation, and 33 percent want faster decision-making. Improved worker safety, enhanced sustainability or lower energy usage, and reduced downtime also rank among the desired results. Investment levels are rising to match those expectations. Cisco reports that AI accounts for 12 percent of manufacturers’ IT and OT budgets, and 83 percent of organizations plan to increase that investment. As budget allocations grow, expectations rise as well. The report notes that organizations committing higher shares of IT/OT budgets to AI are more likely to expect outcomes within a year. Current investment priorities begin with process automation and efficiency, cited by 46 percent of

respondents. Supply chain and logistics optimization follows at 36 percent, with industrial cybersecurity at 30 percent, automated quality inspection at 29 percent, energy optimization and sustainability at 22 percent, and industrial networking at 21 percent. The technologies manufacturers see as most critical to enabling AI also reveal where the industry is heading. Robotics and autonomous systems lead at 54 percent, followed by AI vision systems and cameras at 46 percent, industrial wired and wireless connectivity at 42 percent, advanced sensors at 42 percent, edge computing platforms at 35 percent, and digital twins or simulation tools at 33 percent. In other words, scaling AI is not just a software challenge. It depends on the physical and digital infrastructure that connects machines, sensors, cameras, robots, people, and data.

AI Runs On The Network One of the report’s clearest messages is that industrial AI depends on industrial network readiness. As AI workloads expand across manufacturing environments, performance and scalability are shaped by the infrastructure beneath them. Ninety-six percent of manufacturers expect AI workloads to affect their industrial networks. The top network requirement is more reliable connectivity, cited by 49 percent of respondents. Greater edge computing capacity follows at 44 percent, and higher bandwidth needs are cited by 39 percent. Manufacturers also expect a greater need for wireless connectivity and mobility, network segmentation, higher Power over Ethernet wattage, more PoE ports, and more predictable latency. INDUSTRIAL MACHINERY DIGEST.COM

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These findings underscore the difference between experimenting with AI and operating AI at production scale. A pilot may work in a controlled setting. A scaled deployment has to function across factory floors, warehouses, remote sites, mobile assets, vision systems, robots, and control environments. It must also do so with predictable performance. Wireless reliability is already a constraint. The report says 56 percent of manufacturers report that a lack of reliability frequently affects operations for AI-enabled mobility-related applications. At the same time, 96 percent say wireless networks are critical to enabling industrial AI. Manufacturers also identify specific networking challenges that limit AI-enabled operations. Security and segmentation rank first at 46 percent. The management of different networks follows at 38 percent, and lack of collaboration between IT and OT teams is cited by 34 percent. Lack of PoE infrastructure for vision systems and predictable latency are each cited by 31 percent, followed by bandwidth limitations and roaming or mobility. AI vision systems are putting particular pressure on power infrastructure. The report says manufacturers expect Power over Ethernet demand to increase by 41 times as AI vision systems are deployed. That signals a significant rise over current infrastructure requirements and shows how AI can change the physical requirements of the network edge. Cisco frames the network evolution required for scaled AI in three stages: connect, enable, and scale. First, manufacturers need reliable wired and wireless connectivity with enough power, bandwidth, and coverage to bring assets and data online. Next, they need predictable latency, network segmentation, and edge compute capabilities that support real-time AI workloads. Finally, they need unified, secure IT/OT network architecture that delivers consistent policy, visibility, and cybersecurity across environments.

Cybersecurity As Barrier And Enabler Cybersecurity is both the leading barrier to industrial AI adoption and one of the areas where manufacturers expect AI to create value. Forty percent of respondents cite cybersecurity concerns as the biggest obstacle their organization faces in adopting AI. Lack of skilled talent follows at 38 percent, with technology integration challenges at 32 percent and budget constraints at 28 percent. The report describes cybersecurity as a non-negotiable requirement that determines whether AI can move from pilots into live, safety-critical operations. Ninety-eight percent of manufacturers say cybersecurity is somewhat or very important in AI-ready infrastructure deployment. Among mature or scaled adopters, the report says that emphasis strengthens further, with 86 percent identifying cybersecurity as very important. The threats manufacturers worry about reflect the complexity of connected production environments.

40 | IMD July 2026

Data breaches or data loss top the list at 48 percent. Supply chain or third-party attacks and ransomware or malware attacks are each cited by 37 percent. Unsecured or misconfigured connected devices are cited by 31 percent, while phishing or social engineering and compromise of industrial control systems or OT environments are each cited by 28 percent. Those concerns are not separate from AI strategy. As AI expands across machinery, sensors, suppliers, systems integrators, edge platforms, cloud environments, and industrial control systems, cyber risk becomes part of the deployment architecture. At the same time, manufacturers increasingly view AI as part of the cybersecurity answer. Eighty-one percent expect AI to improve their cybersecurity posture. The report notes that manufacturers see the greatest benefit when AI and cybersecurity are designed together instead of being treated as separate initiatives. That point is critical for manufacturing leaders. AI scale cannot be separated from secure infrastructure, data governance, segmentation, visibility, and incident response. The same connectivity that enables AI also expands the attack surface. The organizations that scale successfully will need to make cyber-resilience part of the foundation, not a later add-on.

IT/OT Collaboration Determines Scale The operating model behind AI matters as much as the technology. Cisco’s report makes clear that IT/OT

Manufacturers are confident about AI’s future, but the report suggests that transformation will happen selectively rather than all at once. Ninety-three percent of manufacturers say they are confident in their ability to scale AI across operations. Ninety-two percent are confident in their ability to meet compliance requirements for AI. Eighty-four percent say AI has already had a significant impact on the industry, and 80 percent say companies that do not invest in AI now will fall behind their competitors. Even with that confidence, most manufacturers do not expect AI to transform the entire enterprise in a single leap. Forty-seven percent expect significant transformation of select processes over the next five years. Thirty-three percent expect enterprise-wide transformation, 18 percent expect incremental improvements, and 2 percent expect AI to play a minimal role. That finding reflects the way industrial transformation usually happens. Manufacturers will apply AI where the operational case is strongest, where data is available, and where the supporting infrastructure is ready. Production, quality, supply chain, energy, safety, and maintenance are likely to be transformed process by process as organizations build the network, security, governance, and collaboration required to scale. collaboration is a major factor in AI outcomes. Manufacturers report generally positive levels of collaboration between IT and OT teams, but alignment remains uneven. Forty-three percent of manufacturing organizations show little to no IT/OT collaboration, a figure slightly higher than the 41 percent reported in Cisco’s 2024 industrial networking research. That gap has consequences. The report links weak IT/ OT collaboration with lower confidence in cybersecurity for AI-ready infrastructure, greater wireless instability, lower network reliability, and slower deployment timelines caused by fragmented ownership. Manufacturers with more aligned digital and operational teams are more likely to show confidence in scaling AI and integrating AI while maintaining regulatory compliance. Collaboration is not just an organizational issue. It affects how confidently AI can be operationalized in manufacturing environments. The skills manufacturers identify as critical to scaling AI also show why collaboration is essential. AI/ML model development leads at 46 percent, followed by industrial networking and security at 38 percent, data science and analytics at 36 percent, cloud and edge architecture at 34 percent, and OT domain expertise at 28 percent. No single group owns all of those capabilities. AI at scale requires knowledge of models, data, security, connectivity, edge infrastructure, operations, compliance, and production realities. That makes IT/OT alignment a practical requirement.

Priorities For Manufacturing Leaders

Transformational, But Process By Process

For More Information: www.cisco.com

Cisco’s report closes with three priorities for manufacturing leaders. » First, treat AI as an operational capability, not an innovation program. AI initiatives should be governed and funded as part of core operational strategy, with success measured in resilience, efficiency, and system performance. » Second, build cyber-resilience and data governance into AI scale from the outset. Scaling AI safely depends on investing in security, segmentation, visibility, data controls, and governance alongside AI capability. » Third, align IT and OT around infrastructure. Collaboration should be anchored around shared responsibility for secure, resilient infrastructure rather than isolated use cases. For manufacturers, the report’s message is clear. AI adoption is already underway, and the business case is increasingly tied to productivity, cost reduction, quality, safety, sustainability, and competitiveness. But scaling AI depends on more than models and applications. It depends on the network, the edge, the data, the security architecture, and the operating model that connects IT and OT. Industrial AI may be moving from pilot to production, but sustained value will come from the manufacturers that treat AI as a core operational capability and build the infrastructure to support it.

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IMD | 41

Tooling & Workholding

TOOLING AND WORKHOLDING Precision in Action Tooling and Workholding is the cornerstone of precision manufacturing, ensuring that materials are securely held and processes are executed with unparalleled accuracy. This section highlights the latest innovations in clamps, chucks, collets, and magnetic workholding, alongside advancements in rotary tables, toolholders, and modular fixturing systems. Together, these solutions enable manufacturers to achieve repeatability, reduce setup times, and enhance overall productivity. From versatile milling and turning tools to specialized threading and gear-cutting instruments, this category delves into the diverse range of equipment designed to meet the unique demands of every operation. Whether exploring robotic end-effectors for automation or custom fixtures for intricate designs, Tooling and Workholding underscores the critical role these components play in driving efficiency and precision across the manufacturing spectrum.

42 | IMD July 2026

The Science Of Tool Holder Concentricity Small amounts of runout can quietly cause scrap, poor surface finish, and shortened tool life long before the problem becomes obvious on the shop floor.

t is a familiar issue for experienced machinists. A production run begins to drift out of tolerance with no obvious cause. Resetting tool offsets may seem like the logical first step, but the adjustment does not solve the underlying problem. In many cases, the issue begins before cutting starts: poor tool holder concentricity. Tool holder concentricity is the alignment between the tool holder’s centerline and the machine spindle’s axis of rotation. Even a small misalignment can affect the entire machining process. A

deviation as small as 0.0001 inch can compromise part quality, shorten tool life, and create costly rework during production. Understanding concentricity requires looking at several related factors, including total indicated runout, spindle accuracy, tool length, and the way the tool holder clamps and supports the cutting tool.

Understanding Total Indicated Runout Total indicated runout, often referred to simply as TIR or runout, measures how much a tool, holder,

or part deviates as it rotates around its centerline. In simple terms, TIR shows how much the rotating element wobbles, runs out of round, or moves away from its intended axis.

A higher TIR indicates lower concentricity. To measure TIR, a dial indicator is positioned against the surface being checked, and the spindle is slowly rotated through one full turn. The operator records the lowest and highest readings and calculates the difference between them. For example, if the indicator ranges from -0.0004 inch to +0.0002 inch, the TIR is 0.0006 inch. Runout should be checked at multiple points, including the holder nose, mid-shank, and tool tip. If the tool holding system is concentric, the readings should remain consistent and close to zero. If they vary, the readings can help identify where the error is being introduced.

Concentricity, Accuracy, And Spindle Performance Concentricity and accuracy are closely related, but they are not the same. Concentricity focuses on alignment. It describes how closely one center axis aligns with another. In machining, that typically means the relationship between the spindle, tool holder, collet, and cutting tool. Accuracy focuses on location. It describes how closely a part size, position, or feature matches the intended dimension. Spindle accuracy is the foundation of tool holder concentricity. Errors at the spindle, including runout, vibration, taper wear, or thermal growth, become root causes of poor concentricity at the tool. A stable spindle provides a consistent center of rotation and supports the tight alignment needed for precision machining. The lever-arm effect makes spindle accuracy especially important. In a machining setup, the spindle acts as the fulcrum. A small amount of movement or misalignment at the spindle can grow as it moves farther out through the tool holder and cutting tool. The longer the tool or gage length, the greater the potential effect. That means a small error at the taper can become a much larger issue at the cutting edge.

How Runout Shows Up In Production Runout can create problems on both the cutting tool and the workpiece. On the tool side, runout causes uneven insert or cutting-edge wear. One edge carries more load than the others, which can rapidly shorten tool life and make tool performance unpredictable. On the part side, runout causes inconsistent material

44 | IMD July 2026

removal. Finished parts may fall outside tolerance, while surface finish can degrade due to chatter marks, uneven textures, or tool instability. The result is often scrap, rework, or additional inspection time. Because runout may first appear as dimensional drift, machinists may be tempted to continue adjusting offsets. But if the spindle, holder, collet, or tool assembly is not concentric, offset changes only mask the symptom. Checking spindle accuracy and tool holder runout early is a critical step in maintaining a stable process.

The Role Of High-Precision Collet Chucks High-precision collet chucks help reduce runout by providing uniform 360-degree clamping around the tool shank. This support helps center the tool as the collet closes and improves repeatability from one tool change to the next. BIG DAISHOWA manufactures high-precision collet chucks with guaranteed runout of less than 0.003 mm, or 0.00012 inch, at 4xD. The company offers collet chuck solutions for machine tool spindles used across precision machining applications.

Several design factors help reduce TIR in high-precision collet chucks. Ground bore concentricity ensures the tapered bore remains concentric to the collet pocket, helping the collet seat true inside the holder. Consistent collet seating helps the collet return to the same position during each tool change. If the collet seats differently from one setup to the next, TIR becomes unpredictable. Balanced clamping force helps draw the tool straight to center as the collet closes. Uneven clamping force can push the tool off center during tightening, introducing runout before cutting begins.

Building Repeatability Into The Process Consistent tool holder concentricity is not only a tooling issue. It is a process stability issue. When the spindle, holder, collet, and cutting tool are properly aligned, the machining process becomes more predictable. Tool wear is more even,

surface finish improves, and parts are more likely to remain within tolerance throughout the production run. For shops working to reduce scrap, improve tool life, and hold tighter tolerances, runout should be treated as an early diagnostic point rather than a last resort. Before changing offsets or adjusting the process, the tool holding system should be checked for concentricity. Precision machining depends on repeatability, and repeatability begins at the spindle. By controlling runout at the source, manufacturers can improve accuracy, protect cutting tools, and create more stable CNC machining operations. For More Information: www.bigdaishowa.com

DILLON MANUFACTURING

Reversible Hard Jaws Support ID and OD Workholding Dillon Manufacturing’s reversible hard jaws are designed for ID and OD workholding, helping reduce the time and cost of tool setups while accurately gripping and locating workpieces. The jaws are intended to hold a specific range of part sizes and are typically used for first-operation workholding.

They are manufactured from 8620 case-hardened steel with ground locating surfaces and a black oxide coating for corrosion resistance. Available in serrated, Acme key, square key, and tongue-and-groove styles, the jaws are designed to fit all brands of chucks. Single- and two-step jaws feature diamond-shaped serrations for secure gripping and accurate part location. Dillon also offers custom special or modified hard jaws with expedited turnaround times. For More Information: www.dillonmfg.com

Find out if your drawbars still Clamprite. Call today! www.clamprite.com

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IMD | 45

FISCHER USA

D17 Milling Head Targets Precision 5-Axis Applications

ESCO TOOL

COHOG Split Frame Machine Adds Modular Tooling Systems

FISCHER USA will introduce its D17 milling head to the North American market at IMTS 2026 in booth 237470. The compact milling head is designed for light- and medium-duty precision 5-axis applications, including composite and aluminum milling. FISCHER USA will display the D17 under the theme “Technology Leader for Precise, Fast and Powerful Rotation.” The company has more than 85 years of experience in high-performance machine tool spindle design, in-house manufacturing, and repair services. “The aerospace industry has been long awaiting this smaller, compact, and versatile head,” said Doug Kranz, vice president at FISCHER USA. “We have invested several years right-sizing this design with focus on lighter-duty composite and aluminum milling applications.” The D17 is optimized for HSK-63 spindles and is capable of speeds up to 30,000 rpm, with 40 kW of power and 39 Nm of torque. Its lightweight, compact design supports applications requiring agility and precision in tight spaces and intricate machining tasks. For composite applications, the D17 can be configured with an integrated suction system and CNC shroud control. The milling head is designed for both straightwater applications and dry environments. At IMTS, FISCHER will display its largest milling head, the D27, its compact D17 milling head, and its branded spindles for milling, drilling, and grinding operations. For More Information: www.fischerspindle.com

ESCO Tool has introduced a new line of modular tooling systems for its COHOG split frame machine. The tooling systems feature a simple trip mechanism and are designed to simplify setup changes for parting and beveling. The COHOG Split Frame Machine features a range of bevel modules that bolt directly onto a tool slide and use two-sided TiN-coated blade inserts to increase blade life. The system is capable of parting and beveling simultaneously. Tool slides are fixed in the carriage with a preset gib plate that eliminates side-to-side wobble for smooth, chatter-free operation. The machine squares itself to the pipe with clamps and is available in eight sizes for pipe ranging from 2 inches to 48 inches O.D. Available bevel modules include a primary parting module, secondary parting module, 37.5-degree bevel, 30-degree bevel, 10-by-37.5-degree bevel, and 10-by-30degree bevel. The simple trip mechanism features a marked pin location that matches all tool slides. The COHOG Split Frame Machine is available for sale or rent, with pricing starting at $14,995 depending on size. For More Information: www.escotool.com

46 | IMD July 2026

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