Ma 2017may de by Annex Business Media

3D PRINTING: Acquisition expected to help Canadian manufacturer ramp up innovation. p.20

SHOW RECAP:

Automate 2017 highlights include cobots, smart machines and virtual reality. p.24

BACKSTORY: The necessity of using planning and scheduling software to measure improvement. p.30

A SKILLED WORKFORCE

MAY 2017

How an Ontario machine shop finds, trains and retains its next generation of employees p.16

MAY17 AC Branding Front Cover Banner (MA).qxp_Layout 1 4/20/17 3:32 PM Page 1

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May 2017 Vol. 32, No. 3

DEPARTMENTS 4 From the editor 5 Automation upfront

The latest industry news, deal makers, and movers and shakers

15 Centre stage

Carole Franklin, director of standards development at the Robotic Industries Association

COLUMNS 10 Industry watch

A generation starving for meaning

CONTENTS

12 Going digital

COVER STORY

Close your talent gap with collaboration

16 Training and retaining

14 Machine safety

Developing a cohesive safety and security strategy

30 Backstory

Using planning and scheduling software to measure improvement

20 Productivity gains

Recent acquisition emphasizes the importance of new technology By Treena Hein

22 Sustained identification

NEW PRODUCTS 26 Communications & networking 26 Machine safety 27 Data acquisition 27 Power supplies 28 Material handling 28 Motion control 29 Process control 29 Wire & cable

How to find, train and keep a skilled workforce By Mary Del Ciancio

Direct part marking for today’s manufacturers By Salay Quaranta

24 Ready, set, automate

Cobots and smart machines top the list of Automate 2017 highlights By Alyssa Dalton

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FROM THE EDITOR BY ALYSSA DALTON

NOTABLE TWEETS

Your resource for Canada’s industrial automation news

@schmarzo Transitioning to “smart.” How the connected industry can help you predict and prevent failures: ln.is/automationmag.com/84lFC @David_W_ Green Interesting… RT @AutomationMag News » #Bombardier and #Siemens in talks to merge train operations: bit.ly/2p4lOfQ ADVANCED WARNINGS: How the connected industry can help you predict and prevent failures. p.20

CYBERSECURITY: Keeping your plant floor secure in the Industrial Internet of Things era. p.12

PM 40065710

SOFTWARE: Why small business environments cannot follow the enterprise approach. p.24

MARCH/APRIL 2017

DOMESTIC INVESTMENT Ontario manufacturer purchases a new vertical machining centre, slashing lead time and internal costs. p.16

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MA_mar_Apr_ 2017.indd 1 MA_AlliedCover_JanFeb .indd 1

2017-04-17 1:56 PM 2016-12-21 9:16 AM

@HitachiSolCa Manufacturers are investing in #IoT tech. See our take on predictive analysis and machine learning in @AutomationMag: ow.ly/ KflI30bgzan @YushinAmerica Great advice from Magic Johnson! RT @ AutomationMag #Automate2017 Magic Johnson’s advice for success: “Never stop learning, strive to be and do more - it will only make you better and better.”

‘Automate or evaporate’

automation, they will not be around in the future.” “The key message is the optimism about jobs in the future, especially with technology,” noted Jon Battles, Amazon director, WW Engineering Advanced Technologies. Earlier this year, the online retailer powerhouse announced it would create 100,000 new full-time jobs in the U.S., ranging from software development to warehouse work. “I want to make a really critical point — we are doing this level of hiring after installing 45,000 Amazon robotic systems in our fulfillment centres. I don’t have any better success story to give than that, and we are hiring in every job class and level...I hope we all internalize the importance of inspiring this young generation coming up, retraining the people we have, giving them a great vision for careers in the future and following through on that. I am very optimistic about the future and the jobs and the technology. As long as we embrace it, and train for it correctly, we have an awesome future,” continued Battles. A new generation in manufacturing is here and companies of all sizes can leverage the transformative technologies the pivotal fourth industrial revolution brings — machine connectivity, big data, and smart machines to name a few. As the factory floor continues to evolve, automation technology is, and will continue to be, the key that unlocks your company’s potential. | MA

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EDITORIAL ADVISORY BOARD AL DIGGINS, President and General Manager, Excellence in Manufacturing Consortium, and Chairman and CEO, Canadian Manufacturing Network DAVID GREEN, Technology and Business-to-Business Consultant KARIN LINDNER, founder and owner of Karico Performance Solutions DON MCCRUDDEN, Vice-President, Business Development, Festo DAVID MCPHAIL, President and CEO, Memex Automation NIGEL SOUTHWAY, Business Productivity Consultant and Author on Lean Thinking BILL VALEDIS, Vice-President, Precision Training, Products and Services Inc.

@AutomationMag

Alyssa Dalton adalton@annexweb.com PUBLISHER

hat a thrilling month April has been; publisher Klaus Pirker and I both attended Automate in Chicago and Hannover Messe in Germany, bookending a month of innovation and networking in the industrial automation world. Both events highlighted numerous new product innovations as well as the potential of Industry 4.0 and the future of humans in tomorrow’s integrated factories. At Automate, I attended the World Robotics International Federation of Robotics (IFR) CEO roundtable, which included speakers from half a dozen manufacturing experts, such as General Motors, ABB, Amazon and Applied Manufacturing Technologies (AMT), where executives discussed the impact of human-robot collaboration and emerging automation technologies on manufacturing. “I was at a friend’s plant just outside Detroit with stamping machines. That particular plant is not very large — he has got to have 30 to 40 robots there in automation. The plant had been shuttered in 2007 and he bought it in 2010. He now has over 200 employees in his plant because of automation,” recalled Michael P. Jacobs, president of AMT. “It is very doable by small companies.” Meanwhile, professor Dr. Howie Choset of the Advanced Robotics Manufacturing Institute (ARM) stressed the need for small companies, in particular, to automate their operations with robotics. “These small companies — this is their phrase not mine — automate or evaporate. They know if they don’t embrace

CONNECT @AutomationMag

EDITOR

Occasionally, Manufacturing Automation will mail information on behalf of industry related groups whose products and services we believe may be of interest to you. If you prefer not to receive this information, please contact our circulation department in any of the four ways listed above. The contents of Manufacturing Automation are copyright © 2017 by Annex Publishing & Printing Inc. and may not be reproduced in whole or part without written consent. Annex Publishing & Printing Inc. disclaims any warranty as to the accuracy, completeness or currency of the contents of this publication and disclaims all liability in respect of the results of any action taken or not taken in reliance upon information in this publication. We acknowledge the [financial] support of the Government of Canada.

AUTOMATION UPFRONT

PHOTO: ABB

POWER PLAYS

ABB moves to acquire B&R

New partnership focuses on industrial AI

ABB announced it has reached an agreement to acquire Bernecker + Rainer Industrie-Elektronik GmbH (B&R). The acquisition, expected to close in summer 2017, will create one of the world’s most-powerful industrial automation companies. With this deal, ABB will become the largest industrial automation player in Austria, where B&R has operated for more than 100 years. “B&R is a gem in the world of machine and factory automation and this combination is a oncein-a-lifetime opportunity. This transaction marks a true milestone for ABB, as B&R will close the historic gap within ABB’s automation offering,” said Ulrich Spiesshofer, CEO of ABB. ABB describes this gap as being between machine and factory automation, noting the acquisition will now pair ABB’s interests in robotics, process automation, digitalization and electrification with B&R’s products, software and systems for empowering machinery and factories. B&R provides ABB with industry leadership in Programmable Logic Controllers (PLC), Industrial PCs (IPC) and servo motion-based machine and factory automation. Spiesshofer continued to explain the acquisition fits with ABB’s “Next Level strategy” with its installed base of more than 70 million connected devices, 70,000 control systems and now more than three million automated machines and 27,000 factory installations around the world. On closing of the transaction, B&R will become part of ABB’s Industrial Automation division as a new global business unit, Machine & Factory Automation, headed by current managing director Hans Wimmer. B&R’s headquarters in Eggelsberg will become ABB’s global centre for machine and factory automation.

At Hannover Messe 2017, ABB and IBM announced a strategic collaboration that combines ABB’s digital offering — ABB Ability — with IBM Watson Internet of Things cognitive capabilities to “unlock new value for customers

MANUFACTURING AUTOMATION · May 2017

Robotic systems: Introduced in 2015, the ABB YuMi dual-arm cobot aims to make work between humans and robots a reality.

in utilities, industry, transport and infrastructure.”

Customers will benefit from ABB’s knowledge and portfolio

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2017-04-20 11:24 AM

AUTOMATION UPFRONT

of digital solutions combined with IBM’s expertise in artificial intelligence (AI) and machine learning, they explain, noting that the first two joint industry solutions will bring “real-time cognitive insights to the factory floor and smart grids.” “This powerful combination marks truly the next level of industrial technology, moving beyond current connected systems that simply gather data, to industrial operations and machines that use data to sense, analyze, optimize and take actions that drive greater uptime, speed and yield for industrial customers,” said ABB CEO Ulrich Spiesshofer. “The data generated from industrial companies’ products, facilities and systems holds the promise of exponential advances in innovation, efficiency and safety. We are eager to work in partnership with ABB on this new industrial era,” added Ginni

Rometty, IBM chairman, president and CEO.

Idec acquiring APEM Idec says it has strengthened its position in the HMI market by purchasing APEM, a French group with a wide international footprint, noting that its European presence will expand “significantly” and new industry segments will also be added. With more than US$500 million in total sales, the combined entity has a broad portfolio of industrial automation and HMI products, and access to markets across North America, Europe and Asia. According to Toshi K. Funaki, Idec president, the new company will employ 3,500 people worldwide and will operate sales subsidiaries in 15 countries and factories in 10 countries. “This acquisition is a major step for Idec to establish solid

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“Significant” expansion: Idec says the acquisition will strengthen its position in the HMI hardware market.

foundations for global growth. It provides us with access to new customers, new markets, and greater range of products and services. Combining the two companies, we are a much bigger enterprise with a global reach,” said Funaki. “Thanks to the complementary product offerings, business models and geographical presence of the two companies, we expect significant synergies as we combine the two companies together.” The parties say APEM’s “strong historical presence and reputation” will help accelerate Idec’s growth in Europe, while Idec’s position in Japan and across Asia will open new markets for APEM products, and help to support existing APEM business across Asia. As well, the combined sales teams in the United States will provide “unique opportunities for selling high quality products and solutions to each company’s customer base,” they say. Idec has four main lines of business: industrial and safety, electronics and automation, explosion-proof, and LED. Products within these lines of business are supplied to various industry segments including manufacturing, public transportation, agricultural and energy. These products include industrial controllers, HMIs, sensors, switches, power supplies, LED lighting and others. APEM’s products are primarily

Brandt to save shuttered Saskatoon plant The Brandt Group of Companies has announced it will acquire the Mitsubishi Hitachi Power Systems Canada (MHPSC) facility in Saskatoon, Sask., and subsequent operating assets from Prestige Equipment and Hilco Global. Located in the city’s Hudson Bay Industrial area, the 22-acre parcel, along with its 208,000 sq/ft. manufacturing facility and equipment, will make the

May 2017 · MANUFACTURING AUTOMATION

@AutomationMag

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HMI interface components such as panel switches, joysticks, keypads and LED indicators. These components are assembled into HMI panels by their customers, or by APEM as semi-custom and full-custom HMI panels. Its primary markets include agricultural, material handling, medical, aeronautics, defence and transportation. According to the parties, these products and markets complement Idec’s standard HMI systems and industrial automation products. “With the acquisition by Idec, a new page of APEM history starts. Our product offerings are complementary, which creates a unique opportunity to develop further sales and new products for our existing customers and new ones,” said Grégory Sachnine, APEM president.

2017-04-18 2:15 PM

PHOTO: FORD

transition to local ownership for an undisclosed sum. The plant boasts the largest machining and fabrication equipment in Canada and has produced power generation equipment for customers around the world, including SaskPower, says Brandt. With almost 400 workers already out of work as a result of the plant’s decline and final closure last October, an auction and liquidation would have likely resulted in long-term unemployment for the local workforce. “We realized that it was critically important for us to move quickly,” said Shaun Semple, Brandt president. “When we learned that the Hitachi assets were going be broken up and sold off in spring, we had to act fast or the province would lose a world-class facility and the ability to produce largescale green energy products.” “It is our plan to reintroduce green energy technologies such as

wind turbines to assist SaskPower with its mandate to diversify beyond traditional fossil fuels. We will be sitting down with the provincial government, the City of Saskatoon and SaskPower to see what can be done to save this valuable asset. But, we’re just getting started; there is a lot of work still to be done to guarantee a successful outcome.” The acquisition of this facility will bring Brandt’s manufacturing footprint in the province to more than 500,000 sq/ft., split evenly between Regina and Saskatoon. INVESTMENT

Feds, Ontario to pump millions into Ford operations The federal and Ontario governments are each investing more than $100 million to support a $1-billion partnership with Ford

It will also support Ford’s plan to create a research and engineering centre in Ottawa to develop new automotive technologies.

New hires: The investment will create 300 new jobs at Ford.

Canada. Prime Minister Justin Trudeau and Ontario Premier Kathleen Wynne are announcing the conditional grants of up to $102.4 million each at a Ford engine plant in Windsor, Ont. The Ontario government says the investment will create 300 new jobs at Ford in the province and protect hundreds more. The funding is also aimed at helping Ford establish an advanced manufacturing program that will transform the company’s power-train facility in Windsor.

Mars Canada invests $70 million in expanded chocolate factory Mars Canada has opened its expanded Newmarket, Ont.-facility, which now manufactures and packages the Maltesers chocolate brand. Bringing together manufacturing, packaging and technology from Mars Inc.’s global facilities, the $70-million, 60,000-squarefoot expansion is expected to create up to 30 new full-time jobs, noted Mars Canada. At peak capacity, the facility will employ up to 150 associates. The company says Maltesers produced at the Newmarket facility will be sold across Canada and the United States, where the

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AUTOMATION UPFRONT

product is being launched for the first time, adding that the expansion will be a “key pillar of growth” for its chocolate business. “This expansion builds on Mars’ rich history in Canada and comes at an exciting time for our overall investment and growth in Canada,” said Jeremy Daveau, general manager of Wrigley Canada, a division of Mars Canada. “Our Newmarket facility is the ideal home for Maltesers, with access to a highly skilled workforce, close proximity to the U.S. for export and potential for expansion.” CYBERSECURITY

Study: 96% of IT security pros expect an increase in IIoT attacks A recent study finds 96 per cent of IT security professionals expect an increase in cybersecurity attacks on the Industrial Internet of Things (IIoT). Conducted by Tripwire, a global provider of security and compliance solutions for enterprises and industrial organizations, and Dimensional Research, the study looked at the rise of IIoT deployment in organizations, and to what extent it is expected to cause security problems in 2017. The study found that: • Ninety-six per cent of those surveyed expect to see an increase in security attacks on IIoT in 2017; • Fifty-one per cent said they do not feel prepared for security

attacks that abuse, exploit or maliciously leverage insecure IIoT devices; and • Sixty-four per cent said they already recognize the need to protect against IIoT attacks, as they continue to gain popularity among hackers. “Industry professionals know that the Industrial Internet of Things security is a problem today. More than half of the respondents said they don’t feel prepared to detect and stop cyber attacks against IIoT,” said David Meltzer, chief technology officer at Tripwire. “There are only two ways this scenario plays out: Either we change our level of preparation or we experience the realization of these risks. The reality is that cyber attacks in the industrial space can have significant consequences in terms of safety and the availability of critical operations.” “Greater connectivity with operational technology (OT) exposes operational teams to the types of attacks that IT teams are used to seeing, but with even higher stakes,” said Robert Westervelt, security research manager at IDC. “The concern for a cyber attack is no longer focused on loss of data, but safety and availability.” Respondents were also asked how they expect their organizations’ deployment of IIoT devices to change, and how it will affect their level of vulnerability. The study found: • Ninety per cent expect IIoT deployment to increase; and • Ninety-four per cent expect

IIoT to increase risk and vulnerability in their organizations. • When respondents were broken down by company size, both larger companies (96 per cent) and smaller companies (93 per cent) expect a significant increase in risk caused by the use of IIoT. RESEARCH DEVELOPMENT

Magna commits $5 million to AI research institute Magna says it will invest $5 million into the Vector Institute, a new independent artificial intelligence (AI) research facility in Toronto, Ont., adding that Vector will be dedicated to “cutting-edge exploration of AI, specializing in the transformative fields of deep learning and machine learning.” “From a manufacturing standpoint, leveraging AI can provide human operators enhanced information for decision making and it can automate quality, sorting and material handling to help reduce production costs. AI-enhanced predictive maintenance systems can also enable effective error-free maintenance of equipment which ensures higher machine up-time. As future mobility continues to evolve, AI will play a major role in dynamic decision-making in autonomous driving. Object detection and classification combined with scene segmentation will be key attributes to self-driving capabilities,” notes the company. INTERNATIONAL KUWAIT

Yokogawa wins desalination plant control system order

Risky reality: 90% of respondents expect IIoT deployment to increase. 8

@AutomationMag

Yokogawa Electric Corporation announces that its subsidiary, Yokogawa Electric Korea, has received an order from Doosan Heavy Industries & Construction Co., a South Korean plant construction company, to supply

control systems for Doha phase 1 project to build a reverse osmosis desalination plant in Kuwait. According to Yokogawa, this is the first control system order for a reverse osmosis desalination plant from a South Korean plant construction company. This plant will be built in Doha, which is about 20 km east of Kuwait city, by Kuwait’s Ministry of Electricity and Water. The plant will produce 270,000 tons of fresh water per day, which is sufficient to meet the needs of 900,000 residents, says Yokogawa. For this project, Yokogawa Electric Korea will supply a Centum VP integrated production control system and ProSafe-RS safety instrumented system. The company expects to complete the engineering, installation and commissioning of these systems by December of this year, and the plant is scheduled to start operation in November 2018. DEAL MAKERS

Rittal partners with Cadence Automatisation Rittal Systems has added Cadence Automatisation to its distribution/partner network in Quebec. Specializing in the distribution of high-tech automation, Cadence Automatisation will bring “additional strength” to the solution-selling philosophy of Rittal, they explain. “It is not often that you have an opportunity to add a partner that is offering true value add solutions and a superior level of technical support and service,” said Tim Rourke, president of Rittal Systems Ltd. “Rittal is extremely enthusiastic about the opportunities our combined energy can create.” “Cadence Automatisation is excited by the quality, knowledge and expertise that Rittal will bring to our automation portfolio, so we can continue meeting and exceeding our customers’ demands,” added Marc-Andre Laurin, general manager of Cadence. “We are excited by the global support and service than Rittal can provide.”

May 2017 · MANUFACTURING AUTOMATION

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MOVERS & SHAKERS Linear motion and factory automation technology manufacturer Helix Linear Technologies has promoted David R. Arguin to president and executive team member, reporting to CEO Christopher Nook. In his new role, Arguin will oversee the strategic direction, expansion and operation of the company. Arguin joined the company in 2015 from Haydon-Kerk, where he served for 22 years in leadership roles including plant manager and vice president of business development. London, Ont.-based FreePoint Technologies has hired Steve Mueller to join the business as its new chief technology officer, saying it has “taken a large step towards establishing itself as a leader in machine monitoring technology.” “We are thrilled to have Steve on board at this critical point in our company’s history — and its future,” said Paul Hogendoorn, president and CEO. Described as a “versatile leader and problem-solver with extensive technology expertise and global business acumen that bridges the gap between business and information technologies,” Mueller’s experience spans markets in Canada, the U.S. and Europe. Pilz Automation Safety Canada is welcoming Marcus Graham to the team, where he will serve a base of customers in southwestern Ontario as a senior technical sales representative. Graham most recently worked at Franklin Empire where he managed customer accounts with a focus on retention and growth, says the company, adding that he “brings invaluable technical education

and automations as well as industry experience.” Mentor Graphics chairman and CEO Dr. Walden C. Rhines has been named a Fellow of the Institute of Electrical and Electronics Engineers (IEEE), where he is being recognized for leadership and technology innovation in integrated circuit design and automation. During Rhines’ time at Mentor Graphics, revenue has nearly quadrupled and enterprise value increased eightfold, said the company, adding that he has built positions in areas outside of traditional EDA, including system design, embedded software, automotive and hardware emulation. The IEEE Grade of Fellow is conferred by the IEEE Board of Directors upon a person with an outstanding record of accomplishments in any of the IEEE fields of interest. C

Harting says it expects to leverage the extensive engineering background of Carl Maalouf — its newly appointed head of Canadian sales — to expand its presence in the Canadian market. Maalouf graduated from McGill University with a B.Eng. degree in Chemical Engineering and is fluent in both English and French. He joins Harting after eight years in technical sales and key account management. MY

CMY

Wago has named Sergio Vergara senior sales and application engineer of eastern Canada. “I’m excited to be a part of a company that focuses on the development of its people and that has a strong corporate culture. Within that, I look forward to learning about new technologies and developing a new set of skills in order to meet the expectations of the market,” he said. | MA

MANUFACTURING AUTOMATION · May 2017

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INDUSTRY WATCH BY PAUL HOGENDOORN

Paul Hogendoorn is the co-founder of FreePoint Technologies, “Measure. Analyze. Share.” (Don’t forget to share!). He can be reached at paulh@getfreepoint.com or www.getfreepoint.com.

A generation starving for meaning

“

Ten nuggests for $1.99, I’m going to text my mom!” I can’t watch this ad without being saddened. We have a generation that has more access to more information than any generation ever before, but it’s a generation that seems to have difficulty getting engaged in anything meaningful. I admit that it’s a very general statement, and not everyone can be painted by the same broad brush, but I sense there’s a lack of meaning in much of our young world today, and ads such as this only serve to illustrate that point: “I’m going to text everyone I know!” Advertising and eating fast food is not what this column is about, but rather acknowledging that it is going to be a challenge for employers — manufacturers in particular — to meet the needs of the coming young workforce. As older folks retire, we need to be able to attract, and then retain, a workforce that is very different from the preceding generations. They have different motivations, different needs, and different ways of looking at things. And the one thing they need, more than any previous generation, is meaning. This generation is starved for meaning — they have a huge appetite for it, but it’s not being filled. “A people without vision are doomed to perish.” This vision isn’t going to come from a political party or a government, it has to come from you and I — the people that help build businesses, communities, homes and families. Wherein the past, youth may have looked to political and government leaders for vision, the same does not hold true today. The older generations remember leaders like JFK and MLK, not just for their charisma and status, but for the vision they cast that set the course for generations afterward. That kind of political vision has not been seen for a long time. Many of our companies today are still led by visionary leaders, but that vision needs to be connected directly all the way to the plant floor — not indirectly through management systems, or policies, or vision statements or slogans. For the millennials more than any generation before, the vision needs to be compelling and backed up 10

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by consistent and congruent action. It’s not about how they might spend the money they make as it is about how they spend their time. One local manufacturing company I know hires a dozen young people at a time, hoping that two or three will stay beyond three weeks. The ones that leave would rather flip burgers at minimum wage than do a repetitive and disengaging job that To attract this pays far more. It’s the time they spend at their job that they measure, not the generation, money they make at it. our manuIt’s also a generation used to constant facturing communication, even if it’s mundane. jobs need to (“I’m going to text my mom” as an exbe more enample.) The old paradigm of having one gaging, and group do the work while another group they have to measures their performance — without have more sharing it in real time — does not line meaning. up well with their life experience or their expectation. To attract this generation, our manufacturing jobs need to be more engaging, and they have to have more meaning. It doesn’t have to be a “change the world” kind of meaning, but there has to be more of a reward to doing the job than just a paycheck. If they are a mother or father with children to feed and bills to pay, going home with a paycheck every week is reward enough. But, if they don’t own

that kind of responsibility in life yet, the paycheck is nice, but it’s not the be all and end all. The time spent at their job is as important as the money they make at it. In the next decade, our manufacturing companies need to pay attention to this difference and make the workplace a more meaningful place to be, and the jobs more meaningful things to do. If we don’t, they’d rather work someplace else, perhaps serving up chicken nuggets for $1.99. It’s time to reconnect meaning with work. Three suggestions for improving engagement: 1) Make sure goals are related directly to people’s specific activities and the measurements are visible in real time. Last week’s measurements are old news, if it’s even news at all. 2) Identify the company’s core ‘people’ values, and live them out demonstrably, outside of the company as well as inside it. What is your company doing in the community or for special causes? Let your people adopt it and share in that. It brings added meaning to the workplace. 3) Provide ample channels for feedback, opinions and input. Be intentional about acknowledging it, even if you are not acting on it. | MA May 2017 · MANUFACTURING AUTOMATION

GOING DIGITAL BY RICK HUIJBREGTS

Rick Huijbregts is the vice president of digital transformation and innovation at Cisco Canada. He leads a team responsible for fuelling the digitization of customers across the country. He can be contacted at rhuijbre@cisco.com.

Close your talent gap with collaboration

his article was originally going to focus on how collaboration solutions — technologies that allow us to connect via voice, messaging and video — are helping manufacturers resolve issues on the plant floor faster and for less money. Then The Future of the Manufacturing Labour Force in Canada report was released and revealed Canadian manufacturers are facing a talent gap of 129,000 skilled workers by 2026. Skilled employees currently on the factory floor are, on average, older than the overall labour force — in some communities, 20 per cent are over the age of 55. We are about to lose many of the senior leaders on our factory floors. We do not have the talent to replace them. This impending skill shortage is attributed to a need for better education and development of these workers, a gap which could be significantly narrowed through on-the-job training. And we aren’t alone. In the United States, a report from the Manufacturing Institute and Deloitte LLC forecasts a potential skills gap of 2 million jobs over the same period. Manufacturers on both sides of the border have a challenge ahead of them: find ways to train young talent with fewer resources and mentors to guide them. Oh, and be sure to keep those young workers after they are trained by providing ongoing career development and education opportunities. It is not going to be easy. But with the right collaboration solutions, manufacturers can close their talent gap. Remote mentorship and expertise

With inexpensive video and meeting solutions, experienced workers close to retirement can mentor younger colleagues, even those thousands of kilometers away, from home. This avoids unnecessary travel for older workers and allows them to share valuable knowledge before retirement. Equally important, this interaction takes place in an environment comfortable for the next generation of leaders — the virtual space. Collaboration solutions extend this remote expert experience to the factory floor by immediately connecting an expert in one location to workers in another when an issue arises. Imagine you had three factories: two in Ontario, one in Quebec. Your most experienced machinists and engineers in Quebec have retired, leaving you vulnerable to downtime 12

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when a machine or line issue occurs. Using video technology, your Ontario engineers connect with those in Quebec immediately and see what is happening, in real time, on the floor. Unplanned downtime is minimized, and inexperienced staff have the opportunity to develop their skills, guided by experts. And for workers close to retirement, their expertise can be leveraged without requiring expensive, time-consuming travel. Education and training Many manufacturers will lose talent in the coming years. Those who prioritize employee education will lose the least talent and will likely be the most successful financially. Enhancing education and training, through interactive, online meeting spaces and twoway video, to connect employees will lead to greater engagement and progress. There are a few reasons for this. First, a large number of employees can be trained at once across all locations. The training can be recorded and used within a syllabus of development courses for new hires. Second, for senior production staff and management, conducting training and development sessions over video vastly reduces the time, and money, spent on multiple in-person events, putting valuable time back on their calendars and money back into the company. Talent acquisition As the labour force ages, millennials are becoming the dominant demographic in the workforce, inching past baby boomers in the U.S., and are accustomed to new ways of working. They regularly communicate with friends

and family over social networks and video and expect similar experiences in the workplace. They are also comfortable using technology and quickly learn how to operate collaboration solutions such as messaging and workspace applications, online meeting spaces and video technologies. Yet according to the 2016 Deloitte Millennial Survey, 61 per cent of millennials plan to leave their current role within the next five years and 75 per cent would like to work from home or do so more frequently. By offering experiences that mirror how these employees prefer to connect, manufacturers can position themselves to better secure and retain talent for years to come. For certain roles, manufacturers should take advantage of the freedom high-definition video solutions can offer remote workers. Interviews can be conducted from anywhere in the world, permitting the best talent to be hired regardless of location. And that same talent can remain remote, conducting meetings with colleagues, partners and vendors from their home while staying connected through voice, messaging and video solutions. This presents an opportunity for manufacturers to look beyond their immediate community for the right employees to meet their needs. The talent gap facing manufacturers is real. It’s not going to go away overnight, and there is no silver bullet solution. But there are steps manufacturers can take to lessen the impact within their facilities, and that starts with the right training and development opportunities for factory workers. And the most effective training and development opportunities will use technology to deliver immersive experiences and empower employees. | MA May 2017 · MANUFACTURING AUTOMATION

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MACHINE SAFETY BY TALEEN MERJANIAN

Taleen Merjanian, corporate marketing manager, has worked in the security and life safety industry with Tyco Integrated Fire & Security for over 20 years. Tyco Integrated Fire & Security, part of Johnson Controls, provides comprehensive fire protection, security and life-safety solutions and services for businesses and large enterprises across Canada.

Five steps for developing a cohesive safety and security strategy

he manufacturing industry is filled with complexities, from dealing with hazardous materials and overseeing intricate processes to managing inventory and seamlessly moving products to the market. With so many moving parts, there is inevitably room for vulnerabilities. In order to help protect your operation, it is important to create a comprehensive safety and security plan before an incident occurs, not after. A proactive security strategy can help to protect your company from losses and ensure your brand’s reputation is not damaged. When building a plan, the first step is to identify the major threats to your company. Top threats for

manufacturing companies • Fire safety risks can include accidental floods, fire damage or an employee injured on the job. These risks can be life threatening to your employees and can cause damaging effects to your business. • With the rise of digital technology, intellectual-property theft can be a major problem. Theft of trade secrets and infringements on patents can negatively affect the success of your business. • Intentional damage to your expensive equipment, known as process tampering, poses a risk to your supply chain and product outcome. • Diversion takes many forms, but can often arise when products intended for one market (domestic or overseas) are sold to an alternative, unauthorized market at a highly discounted price. This can greatly devalue a brand. • Cargo theft, the most prevalent security risk, can occur during any stage of the supply chain, including warehouses,

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containers, truck trailers and couriers. In Canada, cargo theft is a $5 billion problem, according to the Canadian Trucking Alliance. Each year, Canadian carriers have more than $1 billion in losses and claims, as per the Ontario Trucking Association initiative, Best Practices to Prevent Theft. The potential impact of these threats, from both an economic and reputation standpoint, can be detrimental. Building a proactive

security strategy Once specific challenges and vulnerabilities are identified, you can develop your safety and security plan using the following five steps: assess, adopt, access, alert and audit. Assess vulnerabilities You have identified your business’ vulnerabilities, but now you must critically assess them. To do so, pinpoint exactly where vulnerabilities may occur throughout your internal, local and global supply chain. Take into consideration the unique threats posed at each level and target specific points of vulnerability through the lens of life-safety, intellectual-property theft, process tampering, diversion and cargo theft. While some trigger points may be more obvious than others, be strategic and honest with the effectiveness of your pre-existing operations and policies. Additionally, be sure to comply with corporate standards and applicable regulatory requirements. If you operate globally, be aware that each country has its own specific rules and regulations.

Adopt necessary safety measures Security and fire-life safety precautions help to provide vital protection for your people, facilities, products and processes. Customized, integrated fire protection and

security solutions demonstrate your commitment to the highest level of security in the case of an emergency. For example, a monitored fire alarm system notifies the fire department when an alarm goes off to help ensure responders arrive in a timely manner. And with addressable notification features, advanced notification systems with audio control can be programmed to guide occupants to safety. Control access Once you have identified the specific areas of risk in your operations, increase protection by limiting who can access critical control points. These measures restrict who is permitted in designated areas. They give you control and prevent prohibited guests from having free-range of the facility, jeopardizing critical assets. You can prevent unauthorized access to these sensitive areas through integrated video and access control systems. Video surveillance, integrated with access control, allows you to monitor and record security breaches, and better prepare for future incidents. Alert authorities Once you have installed the appropriate security technology and identified critical control points,

another layer of protection is to monitor video surveillance of these points and alert authorities in the event of threats to your facility or employees. Proactive detection and rapid response are critical factors to safeguarding your business. Audit procedures Finally, regular audit procedures help ensure operational and regulatory compliance, and make adjustments in the case of a security breach. This maintains the integrity of your security strategy and technology and ensures that it is dependable. Additionally, regular audits promote a safety culture that ensures the longevity and effectiveness of established best practices. Bringing it all together Manufacturing facilities can help to mitigate even these risks by following these guidelines and implementing a comprehensive security strategy, customized for your unique processes and operations. The key to implementing a successful plan is to integrate safety and security measures into daily operations. As budgetary constraints tighten, it’s important to demonstrate that safety and security measures can be operationalized for optimum value. | MA

May 2017 · MANUFACTURING AUTOMATION

CENTRE STAGE

PHOTO: C. FRANKLIN

Manufacturing AUTOMATION chats with Carole Franklin, director of standards development at the Robotic Industries Association (RIA), about common robot safety misconceptions.

MA: How did you get started in the manufacturing world? CF: I’ve worked in a variety of positions in the industry and in consulting. After I got my MBA from the University of Michigan in 1995, I worked for Ford Motor Company in market research for 10 years or so and then, for about four and a half years, for the consulting firm Booz Allen Hamilton. Our main client at the time was the U.S. army TARDEC, which is the R&D lab for ground systems. They classify robotics as a ground system and as a result, I got to know some of the robotics people there and was really intrigued by the subject matter, so when I saw this position open up, I thought I’d give it a shot. Although it seems a bit eclectic, [my career] has been mostly focused on communicating and translating between non-technical and technical people. [In] my role at the RIA, I work with our standards development committees, which are composed of technical experts in the robotics and robot safety field. These committees get together several times a year to come to a consensus on the current best practices we want to codify in our standards. We work closely with ANSI and ISO, and our main standard is ANSI/RIA R15.06-2012 - Safety Requirements for Industrial Robots and Robot Systems, the U.S. national adoption of ISO standard 10218, Part 1, Robots, and Part 2, Robotic Systems. In Canada, our colleagues at CSA have adopted these practices in CSA-Z434-14 - Industrial robots and robot systems. MA: In your opinion, what are some common misconceptions of robot safety? CF: Historically our main

human were to be contacted by it, it would be less likely to injure them. [But even with] those design factors, if you put that robot arm into a system where it is doing an application that is not safe or using an end effector that is not safe, then as a whole, the [entire] system will no longer be operating as collaborative. If you take a collaborative robot arm and attach a welding tip to it, well clearly that whole system would not be appropriate for collaborative use. [Users] must take into account the application the robot arm will be doing, as well as the pose and motion path. Users must [keep in mind] that having a collaborative robot doesn’t mean you get away from the need to conduct a risk assessment. The need for safety peripherals is not going to go away.

standard has focused on more traditional robots and robot systems, where the way to keep people safe was to keep them away using a variety of safeguards — keep the human and the robot separate. In 2016, the ISO Technical Committee on Robotics, TC 299, published ISO/ TS-15066:2016 – Collaborative Robots, which describes the safe use of collaborative robot systems in greater detail. In the U.S. we adopted this as RIA TR R15.606-2016. Some of the misconceptions I’ve observed are around the collaborative robot [cobot] system and what that means. Sometimes [people]

MANUFACTURING AUTOMATION · May 2017

think, “Well it’s a collaborative robot so I don’t need to concern myself with a risk assessment or worry about the robot’s restricted space.” The idea that just because you have a collaborative robot, it is safe without any further consideration is probably one of the biggest misconceptions I’d like to see people be aware of. We need to think of it as a collaborative robot system, not just a collaborative robot. There are design factors that are intended to make a cobot more “inherently safe” than a traditional robot, such as its small size, small payload limitation and rounded corners, so if a

MA: In terms of the process, how are risk assessments different with a traditional versus a collaborative robot? CF: The process would be essentially the same; you need to look at the tasks to be performed and the hazards, and assess the risks associated with that task and hazard pair. If you find something that is a higher risk then you need to develop some mitigating strategies to reduce that risk, do another pass through your risk assessment, and ask if that risk has been reduced to a level that you can tolerate. You keep repeating that [process] until the answer to that question is yes. [Regardless] of whether you’re considering a collaborative robot or traditional robot system, you still need to go through the exercise and make sure you have identified all the risks and if there are any, take steps to mitigate them. | MA AutomationMag.com 15

COVER STORY

TRAINING AND RETAINING How to find, train and keep a skilled workforce BY MARY DEL CIANCIO

Attracting the next generation of workers Barrie Welding and Machine has been in business for more than 70 years, and in that time has grown to become a leader in the fields of welding, fabrication, machining, press repair and automation. The company attributes much of this success to the top industry professionals it employs. “We have 250,000 square feet of manufacturing space. We have equipment that’s worth millions and millions of dollars. But at the end of the day, without the people with the knowledge and the skills to run it, it’s worthless,” explains Smith. This is why the company puts so much effort into finding “good candidates” to join its team. Its strategy includes reaching out to local schools 16

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at the elementary, high school and college levels. For example, it sponsors a grade seven and eight robotics club, which is open to all schools in the area. In addition, it opens its doors to high school students and teachers to educate them on the opportunities in the skilled trades. The company is also heavily involved with the Ontario Youth Apprenticeship Program (OYAP), a School-to-Work program that enables students in grades 11 and 12 to work towards becoming certified journeypersons in a skilled trade, while completing their high school diplomas at the same time. Representatives from Barrie Welding sit on an advisory committee to assess students in grade 11 who are interested in a career in machining. They interview each student and offer co-op positions through the summer and throughout the last year of high school. The company currently has four students in the shop who are in various stages of this program. The typical co-op term has also been an avenue it has explored to “try out” potential future hires. At the post-secondary level, the company has a relationship with Georgian College, also based in Barrie. The college has a machine shop and offers various related courses, including machining and mechanical engineering technology. Representatives from Barrie Welding work with the advisory committees for these programs, and provide input into what they feel is important for the students to learn. The company also offers tours yearround to the students and teachers, and sponsors a scholarship for the college’s Mechanical Technician – Precision Skills program. This involvement doesn’t just benefit the students, explains Smith. “It’s

25+ years

Between 40 and 50 staff have been with the machine shop for more than 25 years.

230 Barrie Welding and Machine boasts a skilled workforce of 230, including 12 apprentices.

a two-way street. It gives us exposure right off the bat to the people who are going to be tomorrow’s tradespeople. And we’re able to get them interested in Barrie Welding as well.” So far, the company’s efforts have been successful. “It’s only been the last three to four years that we’ve really taken that many steps towards [finding apprentices], but we’re starting to reap the benefits already,” says Smith. “It’s a great way to get the exposure and get to meet the May 2017 · MANUFACTURING AUTOMATION

PHOTO: BARRIE WELDING AND MACHINE

he future of the Canadian manufacturing industry depends on a skilled workforce. But attracting, training and retaining young workers, and transferring the knowledge of an older, more skilled workforce, has long been a challenge for manufacturers in Canada. Adam Smith knows this well. Smith, the operations manager at Barrie Welding and Machine, admits the company struggles to find skilled and experienced labourers. It’s for this reason that it puts a great deal of effort into finding qualified individuals for apprenticeship, and on developing the skills it needs in-house with existing employees. This strategy has been successful for the Barrie, Ont.-based company in recent years, enabling it to attract, train and retain a skilled staff of 230, including 12 apprentices.

what’s coming in the door tomorrow. You don’t know what you’re going to be working on. So the more mentors we can spread these people around to, the bigger the base they get,” Smith says.

“We have equipment that’s worth millions and millions of dollars. But at the end of the day, without the people with the knowledge and the skills to run it, it’s worthless.”

up-and-comers and possibly influence them towards coming to us.”

Training and retaining workers Once the apprentice or young worker is on board, Barrie Welding has strategies in place to ensure they are properly trained and develop the capability to problem solve. For example, the company has developed a mentorship program. It matches apprentices and young MANUFACTURING AUTOMATION · May 2017

workers with mentors on the shop floor. Initially they work with their mentors all day, every day, before progressing to a daily check in. In addition, the company doesn’t leave an apprentice with any one person for a long period of time. The apprentices are rotated through several different mentors to give them a well-rounded knowledge base. “The jobbing shop environment requires a really broad knowledge base because literally you don’t know

But when it comes to choosing mentors, Barrie Welding is very selective. Smith explains that the company’s first approach was to have the best tradesmen mentor the apprentices. However, the team quickly learned that the best tradesman doesn’t always make the best teacher. “We needed that balance of skill set combined with a personality type that was conducive to teaching — understanding and patient,” he explains. “A real key to us was finding those skilled guys that had the personality type to be a teacher as well.” The company is also very particular about the type of work it gives apprentices. “The lion’s share of our apprenticeship training is done in our conventional, manual shop,” Smith explains. “We have found in the past that apprentices who have not done that time to learn the basics, when they get in trouble on the CNC equipment, they don’t have that basic knowledge to fall back on to problem solve. So we really make it a point to...make sure that there’s a firm understanding of that foundation before we progress them into the CNC.” The training doesn’t end when the apprenticeship does, though. The company wants to ensure its employees have the skills they need to be successful at their jobs. It will AutomationMag.com 17

COVER STORY

sometimes bring in experts to talk about the latest in cutting tools or coating technologies, for example. In addition, when employees show an interest in developing their knowledge in a certain area, and there’s a local course available, Barrie Welding will cover those expenses and allow them to take those courses to develop themselves. In the end, says Smith, these new skills benefit the company, too. Regular training, competitive compensation and fair treatment are just some of the steps the company takes to retain its skilled workforce. These efforts not only help to ensure Barrie

Welding has a skilled workforce, it also helps ensure it has a happy one.

A success story Clearly its efforts over the years have been successful, as the company has many long-term and highly skilled employees. Between 40 and 50 staff have been with Barrie Welding for 25plus years, and its longest-serving employee has been with the company for 50 years. These employees possess critical knowledge and skills, and now there is a strategy in place so they can effectively pass it on to the next generation. | MA

Mary Del Ciancio is a business writer who has been covering industrial topics for more than 15 years. She is the former editor of Manufacturing AUTOMATION magazine. 18

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AN INNOVATIVE APPROACH TO TRAINING THE TRADES Not all manufacturers have the resources to train young workers. But the St. Clair College Skilled Trades Regional Training Centre, formerly the Valiant Training and Development Centre, does. Over the last eight years, the Windsor, Ont.-based centre has gained notoriety for its Earn While You Learn program, a unique approach that combines work opportunity and training to prepare young people for a job in the skilled trades. The centre joined the college in January of this year with plans to build on the important work that was started by the Valiant TMS Group back in 2008; work that has helped more than 400 students and 36 industry partners to date, and will have helped another 65 students by the end of this year. Mike Ouellette, who was director of training at the Valiant Training and Development Centre, is now general manager at the St. Clair College Skilled Trades Regional Training Centre. He says he is proud of what the centre has accomplished in the last eight years, but notes there is a lot more to be done to meet the industry’s strong demand for skilled workers. “I have companies calling me every day [looking] for people. I can’t train them fast enough,” says Ouellette. “I could train 150 students a year and it wouldn’t be enough to satisfy industry’s need right now.” The Earn While You Learn program is 46-weeks long, and consists of three weeks of in-class training and 43 weeks of training on the shop floor at the centre. During training, the students work

on CAD systems, fully loaded with different types of CAD software. They also train on multiple five-, four- and three-axis machines, learn 3-D solid model machining, and make real parts for the centre’s industry partners. Each student is paid $12 an hour while being trained. Following the program, the students move onto a fulltime, paying job with one of the centre’s industry partners. This approach is helping the many manufacturers that don’t have the time or resources to train employees. “That’s why this training centre is really unique, because we’re saving them from having to train somebody. The only problem is we need to grow this,” Ouellette says. The 36 companies that the centre currently works with are all local, but Ouellette is hoping to add to this list with manufacturers across the province, and invites companies to visit the centre to see how the model works. “I think a lot of companies are frustrated. They don’t know where to find good people,” Ouellette says. “I think when they come to the training centre and see what we do here, they’re going to want to be involved.” The work they do is critical to the future of Canada’s manufacturing industry, says Ouellette, and it’s a model that should be duplicated at schools throughout the province. “We’ve got to remember that what we’re doing here with these students is actually going to keep the companies in business. If we don’t [do this], we’re going to lose to offshore.” | MA

May 2017 · MANUFACTURING AUTOMATION

PHOTO: BARRIE WELDING AND MACHINE

“We’ve got to remember that what we’re doing here with these students is actually going to keep the companies in business. If we don’t [do this], we’re going to lose to offshore.”

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3D METAL PRINTING

Acquisition of Burloak Technologies by Samuel Manufacturing emphasizes the importance of new technology BY TREENA HEIN

n March, Samuel, Son & Co. purchased Burloak Technologies of Dundas, Ont., a prominent Canadian company in the additive manufacturing arena. Leaders from both companies believe this consolidation will equip staff to further ramp up innovation and provide even better service to customers. Founded in 1855, Samuel, Son & Co. now has more than 100 facilities where a workforce of over 4,800 serves tens of thousands of clients in many industrial sectors. Burloak Technologies, founded in 2005, designs, prototypes and develops parts for aerospace, defence and high-tech companies, and has shown itself to be an industry innovator. For example, Burloak was the first company in 20

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Canada to obtain a direct metal laser system for manufacturing, and more recently, it’s pioneered the use of metal 3D printing. Metal 3D printing is disruptive to traditional metal manufacturing on many levels. Instead of producing metal objects through removal of excess material, building objects through metal 3D printing is faster, more energy efficient, and generates very little to no waste. In addition, because the process involves production in layers, often using latticed designs and combinations of metals, parts are also significantly stronger and lighter than parts produced using conventional manufacturing methods. It is estimated that the aviation industry alone has already saved billions of

50%

Burloak president Peter Adams says they have seen weight savings of more than 50 per cent in space and aerospace applications thanks to 3D printing.

dollars, mostly through fuel costs, through using 3D-printed parts. Leaders at Samuel and Burloak believe the acquisition will allow the two firms to provide the strongest independent supply chain solution in the North American market, with plans to deliver 3D metal printing solutions to customers globally. “We’re in the early stages of assessing the synergies that will flow from the Samuel-Burloak partnership, but we do expect significant growth in production over the next few years,” notes Colin Osborne, manufacturing president at Samuel. “At this juncture, it’s hard to put specific numbers to it, but there’s no doubt this is a very exciting, emerging field and demand is going to be great.” Osborne says many of Samuel’s customers have already been exploring what additive manufacturing could mean for their business. “Together, Samuel and Burloak will not only be able to assist customers in understanding that but can also work with them to engineer, prototype and produce parts that will greatly increase May 2017 · MANUFACTURING AUTOMATION

PHOTO: BURLOAK TECHNOLOGIES

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Burloak president Peter Adams and Samuel Manufacturing president Colin Osborne show off a component made from 3D metal printing.

product performance and make unprecedented production enhancements,” he explains. “Another key element of course is the fact that Burloak can now take advantage of Samuel’s sheer size and industry-leading history that will allow it to scale to meet the long-term requirements of customers.”

PHOTO: BSAMUEL, SON & CO.

Customers gain many benefits from the use of metal 3D printing.... including lighter weight, better thermal performance and higher productivity. The companies already have several systems in place for 3D printing both metals and plastics, and are adding new capacity on an accelerated basis. The metals involved include titanium,

aluminum, maraging steels, nickel alloys, invar and stainless steels. Customers gain many benefits from the use of metal 3D printing, says Burloak president Peter Adams, including lighter weight, better thermal performance and higher productivity, depending on the application. “In general, we see weight savings of more than 50 per cent in space and aerospace applications, along with the ability to deliver dramatic improvements in cooling of molds in the plastics industry,” he says. “This can amount to hundreds of thousands of dollars in productivity gains. In the energy sector, we are seeing increasing applications where we can produce geometry that was simply not possible before, providing tremendous efficiency boosts to several processes.” Adams concludes that for Burloak and Samuel, the real beauty of additive manufacturing is the way it allows the large combined team of engineers to deliver solutions to customers that are simply not possible to achieve with traditional manufacturing methods. “It’s a cutting-edge disruptive technology,” Adams says, “that is incredibly exciting.” | MA

Treena Hein (treenahein.wordpress.com) is an award-winning Ontario freelance science and tech writer.

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LASER MARKING

SUSTAINED IDENTIFICATION Direct part marking for today’s manufacturers BY SALAY QUARANTA

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of the component, dot peen tools are subject to wear due to constant impact on material surfaces of high strength. For applications that cannot have an indentation on the component material, ink jet or pad printing may be an option. In ink jet marking, small droplets of ink are released onto the surface of the component and allowed to dry or cure much like an office ink jet printer prints to paper. UV inks, if the application allows, can reduce curing time and minimize the potential for smearing or distortion. Some monitoring of the process is necessary to ensure the ink nozzles do not clog and the cost of ink cartridge consumables must also be considered. With high contrast, resolution and visibility of the mark, manufacturers have a degree of freedom to create graphics and text that could not be accomplished with dot peen. Since the marking sits on the substrate’s surface, however, it may fade, scratch, or delaminate

over time. In addition, some materials are considered unmarkable. For example, the surface properties of certain films prevent the ink from fully curing. In this case, a more permanent method like laser marking is often the answer. Direct part marking with a laser offers manufacturers a truly permanent labelling solution. A variety of platforms and wavelengths to work with, such as infrared, green or ultraviolet wavelengths, ensures a permanent mark is achieved in nearly any material type. As a versatile tool, the laser can produce engravings, annealings, colour changes, or even ablate a select amount of material to reveal the underlying substrate thereby giving a contrast area, for example, in the creation of a barcode. Medical manufacturers that need to implement traceability marks for UDI purposes but also to survive passivation or cyclic autoclaving processes find laser marking to be the only solution. With a short pulse width laser marking system, the mark will be readable at any viewing angle and under the high intensity lights of an operating room. May 2017 · MANUFACTURING AUTOMATION

PHOTOS: TRUMPF

anufacturers increasingly look to add part marking directly into production lines. Some chose to replace traditional processes, like ink printing or dot peening, while others are just looking for a better way to meet traceability requirements in industries across the board. These techniques contribute to lean manufacturing while meeting industry specific standards for unique device identification (UDI). When possible, direct part marking has become the preferred method of traceability as it enables manufacturers to avoid the costly mishaps of traditional solutions, such as labels that peel off or fade with time. There are several options for creating a mark that can be tracked through production to final assembly and remain readable in the field. The ultimate goal is to achieve a mark that ensures the manufacturer’s confidence in sustained identification. Dot peening, a longstanding favourite of the aerospace and defence article suppliers, creates a small indentation on the surface of the component with a metal stylus or “nail head.” The markings are limited to what is achievable with a dot matrix formation which includes basic alpha numeric characters and data matrix codes that contain important product information but not artistic markings, such as logos. The indentation will remain visible even if painted or coated in finishing steps down the production line but can be subject to low contrast against a substrate and therefore not be readable or verifiable by downstream vision systems. While this technique has been proven to be reliable over the lifecycle

Laser marking has nearly no limitations to how small of a character can be marked. For example, when marking an electronic chip, diode-pumped vanadate green lasers can be used to produce a permanent colour change. A bone screw or similar part that comes in contact with biological tissues must have a bioinert mark. A nano-, pico- or femto-second laser can be used to anneal a local area so a traceable part number, screw size number, or logo can be produced on the head of the screw that will remain even after harsh finishing processes like passivation. Laser marking systems are designed for easy integration into any assembly or automation set up. These compact, often aircooled systems require minimal maintenance and can operate in extreme manufacturing environments. The smallest all-in-one designs include the laser, scanner, control unit, and internal focus control in a unit that is roughly the size of a shoebox. Other systems feature detachable connection cables between the processing head and supply unit for easy installation and service. When integrated into a high volume automation line, the system can be mounted in a variety of angles, mark parts on the fly at known or random intervals, and are able to

mark everything from planar to cylindrical shapes. The marking field size can be adjusted quickly with a simple optic change and flexibly accommodate beam expanders, dual-head systems, and vision packages for a more open automation design. Marking the part directly in the assembly line reduces mistakes and subsequent touch points by a production operator. They also easily interface with databases to query production or product identifier information and incorporate barcodes seamlessly in support of lean

Part marking is an integral part of the manufacturing process, from managing and streamlining production within the shop, to ensuring traceability of a part for its lifetime.

manufacturing initiatives. Integration partners can provide customers with the highest degree of safety by choosing laser systems that feature a two-channel safety circuit. Such systems meet all protection requirements for both the processing head and supply unit therefore eliminating additional efforts by the integrator. Part marking is an integral part of the manufacturing process, from managing and streamlining production within the shop, to ensuring traceability of a part for its lifetime. Whether for branding, functional use or traceability, value is created with the mark. Part marking has become increasingly essential in creating an efficient manufacturing environment and by knowing which method to choose, product designers and engineers alike can make their mark. | MA Salay Quaranta is the business development manager for TruMark lasers at Trumpf Inc. in Farmington, Conn.

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Our safety consultants go the extra mile. Pilz Services for Machinery Safety. MANUFACTURING AUTOMATION · May 2017 MA_Pilz_Feb.indd 1

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SHOW RECAP

READY, SET, AUTOMATE Cobots and smart machines top the list of Automate 2017 highlights BY ALYSSA DALTON

Implementing robotics into your operations The ease of interaction with today’s robots was a common theme on the tradeshow floor. At the Kawasaki Robotics booth, attendees were served a refreshing ice-cream cone by the duAro dual-arm cobot, while those with a competitive spirit could battle it out against a robot in an air hockey match at the Setpoint Systems booth. Other exhibitors highlighted the agility and safety features of their cobot, by touching or grabbing it to demonstrate how quickly they can stop when human interference is sensed. The first step to implementing robotics, many robot makers said, is to determine the specific application use. There are several fundamental differences between traditional and collaborative robots which can ultimately affect the average implementation cost, noted Douglas Peterson, general manager of the Americas at Universal Robots. Traditional robots, in general, are fixed assets and are more suited for high volume, low mix production environments and can require a lot of caging, guarding and safety requirements as compared to collaborative robots, which 24

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are typically flexible, lightweight, “easy to deploy, and easy to move around,” he said. “Most cobots...can be plugged 110W AC so you don’t have all that power infrastructure. Yes, you’ll need a little bit of tooling, integration, vision and so forth but in general, a collaborative robot application can be a fourth to a third of the total cost [of a traditional robot installation]. This can be helpful for getting started with robotics when you are a small- or medium-sized enterprise which [do not] always have large capital investment budgets.” Peterson pointed out that new robots should be thought of as an extension of the workforce, not just another asset to be acquired, and must be introduced into the operation the same way new employees are. “Cobots can help you with [a] labour shortage; they can help fill those positions where you may be having trouble finding employees and that moves current employees into more high-value tasks,” he said. “We think of the

cobot as a tool in your toolbox. A lot of our customers take a robot and deploy it in one application, and because they’ve got it on wheels, they cart it over to another machine and now they are tending a different machine for the rest of the shift. They are using the robot as a tool — they are programming it and re-programming it and finding new applications every day for the robot.” Virtual reality makes a splash Several booths featured virtual reality, one of which was Destaco, which highlighted its new Accelerate Vision Virtual Reality (VR) digital design solutions tool. Describing it as a next-generation VR technology, Destaco said the tool will improve end effector production accuracy and speed. “Upon design review, the Accelerate Vision VR tool allows us to create complete process simulations,” explained Stefan Eggers, company vice president, global sales and service. “This key analysis and simulation enables us to capture interface positioning, additional collision points and maximize the press speed. After detailed simulation analysis is verified, we can move to accurately build and validate the end effector tool.” As the speed of manufacturing continues to increase, the design process for these components must also be accelerated while meeting strict demands regarding die-making and May 2017 · MANUFACTURING AUTOMATION

PHOTOS: A. DALTON

utomate, the lively biennial tradeshow and conference, has concluded its 2017 edition, boasting record show attendance of 12,960 attendees — a 37 per cent increase over 2015, show organizers say. With the collocated ProMat and ProFood Tech attendees taking advantage of free entry, organizers say more than 20,000 people visited Automate for four jam-packed days of industrial automation and manufacturing technology, where collaborative robots (cobots), the connected factory, and virtual reality took centre stage. The show, held April 3-6 in Chicago, is organized by the Association for Advancing Automation (A3) and its trade associations, the Robotic Industries Association (RIA), Advancing Vision Imaging (AIA), and the Motion Control & Motor Association (MCMA).

tooling accuracy and precision, stressed the company. I had the opportunity to check out the tool myself (see the bottom photo on the previous page) and it was quite the experience. The VR world was so immersive the second I slipped on the goggles, I almost forgot I was in a buzzing conference hall for a bit! New players enter the marketplace Two of this year’s exhibitors who officially entered the North American market by way of the tradeshow are On Robot and OptoForce. Based in Odense, Denmark, On Robot is a manufacturer of grippers for cobots. Having sold its customizable cobot grippers in more than 40 countries since its founding in 2014, On Robot decided to bring its “more user-friendly, safe and flexible” grippers to North American manufacturers. Its flagship product, the two-finger RG2 gripper — available in single and dual versions — mounts on the arms of cobots without any external wires. The company explains that for robots that have infinite rotation of the last joint, this enables “unprecedented flexibility

and productivity.” On Robot has appointed high-tech distributor Gary Eliasson as its general manager for North America. “The demand for easy-to-use and -program cobots in North America is growing dramatically,” said Eliasson. “But the missing link of the entire collaborative development has been grippers that are as flexible and dexterous as the arm itself. RG2 is that missing link. I’m looking forward to filling the demand with a robust distribution network throughout North America to help manufacturers automate their processes as easily and cost-effectively as possible.”

Bring Your Machine To Life With an Automation Controller Aerotech’s standard controllers are flexible enough to handle almost any application. From the simple motion of this mechanical wasp’s head, to coordinating multiple axes in your machine, Aerotech automation controllers are the answer. Users can program in G code, PLC, .NET (C#, VB.NET), C, MATLAB®, or LabVIEW®. Aerotech will also customize the controller for your needs. Contact an Aerotech Application Engineer today to learn how our automation controllers can benefit your application.

Meanwhile, the Budapest, Hungary-based OptoForce showcased its six-axis force/torque sensors to attendees of the show. Currently compatible with robots from Universal Robots and Kuka, the company is expected to announce compatibility with ABB and Yaskawa later this year. According to Ákos Dömötör, CEO of OptoForce, the sensors automate a range of high-precision work — such as polishing, box insertion, and other finer assembly tasks — promising to increase efficiency, speed project development, and decrease production costs. Dömötör said the move toward cobots has been propelled by the need to have industrial robots that are sensitive, agile, precise and smart. “With robots working more closely with humans, they need to accurately and precisely sense their surroundings and accomplish many tasks requiring the dexterity and sensitivity of the human hand,” he said, noting that this will help manufacturers who have “long offshored production due to high labour costs and the traditionally high cost of automation. The [show response] has been very good; it’s been very busy for us.” | MA

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NEW PRODUCTS COMMUNICATIONS & NETWORKING Machine mount IOLink mini-masters for industrial Ethernet Balluff says its four-port IO-Link masters can connect a multitude of smart devices over IO-Link to build a “truly distributed machine mount controls architecture for today’s automation.” With an IP67 housing, theIO-Link masters can be mounted directly on the machine closer to the sensors and actuators, keeping short cable runs and adding enhanced diagnostics, says the company. EtherNet/IP, PROFINET and EtherCAT version of the masters are available. The Balluff Type A IO-Link mini-master can host up to 120 configurable discrete I/O when connected to Balluff IOLink I/O hubs with an expansion port, says the company, adding that it offers add-on instructions and function blocks to promote ease of IO-Link into the existing controls architecture. www.balluff.us

New informational brochures

Wago has released new product literature for five product groups: • Epsitron power supplies: The power supplies boast constant supply voltages for a variety of industrial applications, now with multiple mounting options; • 811 Series: Class CC and Midget fuse holders with lever actuation • Power Cage Clamp: Now with a panel-mount variant, high-current terminal blocks promise to offer convenience 26

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and reliability in industrial applications up to 350 kcMil; • XTR: The Wago-I/O-SYSTEM 750 XTR family of PLCs and I/O modules aim to withstand extreme climatic conditions such as vibration, impact and surge voltages; and • Jumpflex: Four new signal conditioners boast flexibility and adaptability for a myriad of applications. www.wago.us

14, 16 bit multi-channel LXI digitizers Spectrum Instrumentation has released a range of highspeed 14 and 16 bit LXI-based digitizer products for various

applications where multiple electronic signals need to be acquired and analyzed Spectrum. Twelve new instruments with up to 24 fully synchronized channels extend Spectrum’s digitizerNETBOX family. The 16 bit ADC models offers sampling rates of either 130 MS/s or 250 MS/s, while the 14 bit units feature sampling rates of 500 MS/s. According to the company, the high sampling rates and resolutions make the DN6.44x series “perfect for wide-band signal capture,” noting that the high channel

density makes the instruments suitable for applications where arrays of receivers, sensors, detectors, rectifiers, antennas and other electronic devices are to be used and tested. The ADCs on each channel are clocked synchronously, says Spectrum, adding that each channel is also equipped with its own front-end amplifier that features six input ranges (from ±200 mV up to ±10 V full scale), switchable input impedance (50 Ω and 1 MΩ) and programmable positive input offset for unipolar signals. www.spectrum-instrumentation.com

the machinery cannot restart until the switch is reset. The switch is reset by turning the blue reset dial from the Off position to the run position. www.rockfordsystems.com

VAC models and a 200kA short-circuit current rating, AutomationDirect says the devices are ideal for use in ANSI/ UL Type 1 or 2 SPD installations, such as AC distribution, drive protection, control panels and more. The devices are UL and CSA approved. www.automationdirect.com

MACHINE SAFETY Emergency-stop assembly Rockford Systems, a provider of machine safeguarding products and services, has introduced the CML510 cable and push-button emergency stop (e-stop) assembly boasting a “unique” cam operation to deliver faster positive stopping of machines. The assembly is also effective as an awareness barrier on the backside of shears and press brakes, as well as around the perimeter of other hazardous areas for reducing risk, says the company. The e-stop assembly includes a pushbutton switch with red mushroom-head button, indicator light and bulb, 21 feet of red PVC-covered steel cable, and cable tension kit. Because the cable is interlocked with the switch, it will actuate an emergency stop if pulled or removed from a hook, leaving the machine inoperable, says the company, adding that

Surge protection AutomationDirect has extended its offering of surge protection devices to include Mersen’s Surge-Trap Type 1 STXR series. Boasting a small, compact design and line or load installation flexibility, the series claims to be the “perfect fit” for branch panel and/or individual equipment protection. According to AutomationDirect, the one-piece device requires no assembly and can be used at the machine or the main panel to protect equipment from downtime and/or damage associated with power spikes and surges. Available in 120-600

Remotely operate a safety system from up to 300 feet away CBS ArcSafe has introduced the SecureConnect Remote Operator for Allen-Bradley Centerline 2100 motor control centres (MCCs) equipped with SecureConnect, allowing technicians to operate the safety system from up to 300 feet away, “well outside the arc-flash boundary,” it says. Designed in cooperation with Rockwell Automation, the 13-pound SecureConnect Remote Operator allows technicians to remotely disconnect an individual plug-in unit or motor control bucket from the Centerline vertical power bus while the enclosure door is closed and from standing up to 300 feet away. www.cbsarcsafe.com May 2017 · MANUFACTURING AUTOMATION

DATA ACQUISITION Long-range reader Pepperl+Fuchs says its new F192 reader can quickly read up to 200 tags at distances of more than 15 feet. The F192 puts out the maximum power allowed by the FCC, 4W EIRP and the output power is adjustable to as low as 10 mW, so the F192 works equally well for shortread ranges, according to the company. The company describes the F192 as a completely self-contained reader, with the antenna, amplifier, and reading electronics all in one — “the advantage of this design is the absence of commercial-style coaxial cables.” The reader uses industrial M12 connection cables, which it says allows operators to run more than 3,200 feet back

to the main control system with no reader performance degradation. A solid cast aluminum base provides universal 100 mm x 100 mm industrial mounting support in addition to shielding against unwanted stray tags behind the reader. Users can operate the unit in ambient temperatures of up to 158 F. www.pepperl-fuchs.us

It’s about time!

Handheld data logger Omega describes its OM-DAQXL series as a portable handheld data logger that delivers “high performance and functionality.” Offering 8 or 16 universal analog inputs, the data logger boasts fast sampling rates, large data storage, and a 7-in. TFT colour touchscreen display promising an “intuitive user interface, easy channel configuration, data logging and play back, and more.” The series is suitable for a range of applications including R&D and industrial labs, chemical, water treatment or HVAC process monitoring and strain measurement during physical testing of materials. www.omega.com

Time to save Time is money. Time saved in engineering can lower costs or be used to generate more revenue. Switching to EPLAN Electric P8 from CAD software typically reduces project time by 40% or more right out of the box. Use the full capabilities of the EPLAN product suite and you could reduce time spent by 80%.

Time to create EPLAN automates time-consuming data creation and verification functions CAD users must perform manually, and often repetitively. And EPLAN has virtually unlimited scalability for managing the increasing demands of designing for the IIOT/Smart Factory environment.

POWER SUPPLIES Programmable AC power source includes DC output capability

remote control, it adds. www.inteproATE.com

AC-DC power supplies with PFC-input Intepro Systems has introduced the AFV-P series of programmable AC/DC power sources, promising clean power with distortion less than 0.3 per cent at 50/60Hz. Available in four power levels – 600VA, 1250VA and 2500VA (2U) and 5000VA (5U) – the series delivers output voltage from 0 to 310 VAC and frequency from 40 to 500 Hz (15 to 1000 Hz with the highfrequency option). The devices can also be programmed to provide DC power from 300W to 2500W at 0-210/0-420 VDC. The units feature 300 µs slew rate (for 0-90 per cent change in output voltage) and can deliver up to 4.5 times peak current (crest factor) from its max rated current. According to the company, the APF-V is ideal for commercial, defence and aerospace test applications, from design verification and quality assurance to automated production testing. Users can remotely control the unit via standard interfaces of USB, RS232/ RS485, LAN or optional GPIB and analog control. Free control software and LabVIEW driver are available for programming and

TIme to switch EPLAN is the future of engineering. It’s freedom to concentrate on what matter’s most – engineering – so you or your team can quickly create high-quality machinery and plant designs and documentation.

Absopulse Electronics has released the PHR series of industrial quality AC-DC power supplies with active PFC-input. The units are designed and built for an operating life of up to 30 years and are ideal for environments where power supply repair or replacement is not feasible, explains the company. The opto-less design boast low component count, large design headroom, full electronic protection, 5000Vdc input to output isolation and heavy ruggedizing. The standard PHR series is available in output power levels of 120W, 150W, 200W or 250W. All power supplies in the series operate at full specification over a -20 C to 70 C temperature range with conduction and convection cooling. www.absopulse.com

For more information or for a free 30-day EPLAN trial, contact us at 1-847-240-4667 www.eplanusa.com info@eplanusa.com

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NEW PRODUCTS MOTION CONTROL Smart Access web server module

The Siemens Sinamics V20 Smart Access web server module, designed to mount directly onto the drive, promises to transform a mobile device or laptop into a virtual operator panel for drive control. By providing a Wi-Fi hot spot, the wireless connection on the module facilitates setup, programming, commissioning, production monitoring and maintenance on a range of machines and production equipment, explains Siemens. An embedded graphical user interface (GUI) enables “easy use” of the Sinamics V20, notes the company, adding that a separate app is not required. A built-in, multi-colour LED promotes quick communication status readout, while security features enable limit/restrict operator access and control functionality. According to Siemens, Smart Access provides access to the Sinamics V20, up to 100 meters away, even when the drive is located in difficultto-access installations. Smart Access allows monitoring of the drive status including speed, current, voltage, temperature and power, as well as drive servicing, with an overview of alarms, faults and individual values. Fault codes can be transferred via e-mail to a local service provider, while the immediate status of all digital and analog inputs and outputs can be checked at a glance. www.usa.siemens.com

Electric linear module Schunk says its ELP can be adjusted in two simple steps, describing it as the most userfriendly electric linear module 28

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on the market. The end positions can be mechanically adjusted with a screw and the speed of extension and retraction is adjusted using rotary switches on the side of the unit. Speed can be automatically adjusted, depending on extension weight and no shock absorber adjustment is necessary, notes Schunk, because the drive automatically regulates the brake process. The company says the linear module is “practically wear-free with a long service life and low maintenance cycles.” The control and power electronics are directly integrated into the

module, and can be controlled by a fieldbus distributor or through digital signals. www.us.schunk.com

Motion control solution boasts small envelope

Grimsby, Ont.-based Handling Specialty says its Smart Arm Manipulator (S.A.M.) is a laser and camera-assisted motion control solution that enables lifting and repeatable positioning of a jet engine Bellmouth within a small envelope. Utilizing a

custom heavy-duty multi-axis manipulator arm, the unit is designed to grasp the Bellmouth with “robot-like precision” and then release once assembled to the jet engine. The S.A.M comes complete with supporting framework of the positioning arm for quick installation, a compact footprint and the ability to lift and hold large payloads, says Handling Specialty, adding that the software is set up to the user’s parameters, programmed with pre-defined movements at Handling’s test facility to ensure easy integration and seamless interface with the user’s equipment and controls. An operator monitors the positioning of the arm via an onscreen live feed camera display. The unit can be designed to lift

MATERIAL HANDLING Pallet-based transport system

Kuka says the system features low susceptibility to faults thanks to a very small number of moving parts; as well, the high transport velocity and flexibility are further advantages of KS PULSE. www.kuka.com

trucks or other direct-to-dock sequencing operations. www.wynright.com

Conveyors with ARB technology

Virtual reality at ProMat 2017 KS PULSE (Propulsion Using Linear Synchronous Energy), the pallet-based transport system for automated assembly lines in body-in-white production from Kuka Systems, promises to quickly and safely move various body components through the individual workstations while reducing non-productive times and downtimes. According to the company, KS PULSE is ideal for high-volume production systems. The main element of the transport system is a carrier. Using various transport platforms, called skids, the carrier transports the individual body components through the assembly line. The carriers are moved through the process stations of the system by means of linear synchronous motors.

Wynright, a wholly owned subsidiary of Daifuku North America Holding Company, demonstrated several 3D virtual reality materials handling solutions as well as a virtual tour of Hini Arata Kan, Daifuku’s technology showcase facility in Japan. An interactive kiosk showcased the company’s material handling solutions and technologies, as well as a series of product demonstrations including robotics, conveyor and sortation, Mini-Load Shuttle and other AS/RS models. The new AS/RS Shuttle solutions are designed to optimize the use of floor space and ensure accurate inventory control. It can store and buffer picked orders and then release them in sequence to load onto route

Dorner highlighted its 3200 series conveyor with Intralox Activated Roller Belt (ARB) technology, along with its SmartFlex and Precision Move platforms, at Automate 2017. The conveyor is suitable for moving boxes and packages in merging, diverting and aligning applications, says Dorner, adding that ARB technology uses low and high friction angled rollers within the belt to help smoothly guide and align items of all sizes. This technology, it explains, minimizes floor space, increases system reliability, eliminates costly system controls, provides a safer work environment. www.dorner.com May 2017 · MANUFACTURING AUTOMATION

WIRE & CABLE other aero-engine components or developed to work in other industries, such as advanced manufacturing, where heavyduty, robot-like movement and repeatability are required. www.handling.com

Design tool for mobile devices

company, adding that the tool was developed by engineers for engineers. www.cicoil.com

Cable assemblies

1:4 speed multipliers Heimatec has announced the immediate availability of its line of 1:4 live tool speed multipliers in 24,000 RPM max. styles, available for live tool lathes currently on the market. These speed multipliers are provided as axial or radial drilling and milling heads, with either external or internal coolant design, and mounting configurations to suit “virtually any machine tool” turret set-up, including all VDI and BMT sizes, says Heimatec. Speed multipliers for Haas and Nakamura machines are now in stock with others in production for short lead time deliveries, it adds. “These speed multipliers are a great addition to our line. They give us more to offer the job shop and large production departments, through our growing network of reps and distributors, serving the market here,” says president Preben Hansen. www.heimatecinc.com

Cicoil says its EZ-Flexx flat cable configurator is now available for use on both Apple iOS and Android mobile devices. Located at www.cicoil.com/flat-cable/ configurator, the free tool allows a user to design an EZ-Flexx Flat Cable “in minutes,” says the

Cable configurator TE Connectivity has introduced a new family of industrial mini I/O cable assemblies, boasting reduced dimensions and an “innovative method” for wire

PROCESS CONTROL Optimizing calibration practices GE Digital’s Meridium has partnered with Beamex to combine its asset safety and data analytics capabilities with Beamex CMX calibration software. Utilizing the Meridium software with Beamex CMX Calibration Connectivity, Meridium’s APM Calibration Management application populates the CMX calibration software with asset hierarchy, calibration profile and receives calibration results and other device data from Beamex CMX. Boasting the best of both APM and calibration management functionality, the integrated

termination, it says, describing the connectors as a reliable and space-saving solution that can be implemented very quickly. TE says a “highly reliable” connection is ensured by two points of contact, enabling the mini I/O connectors to meet the demands of industrial and high vibration environments. www.te.com

solution offers an expanded view of asset health, they say. www.meridium.com www.beamex.com

Weidmuller says its HDC Cable Configurator simplifies the task of designing and building custom cable harness and mating assemblies for its Rockstar heavy duty connectors. The company says the online tool can help users save time and reduce errors, as a single part number is assigned to the completed cable harness and a single part number is created for each mating assembly required for a user’s application. www.weidmuller.com

ADVERTISER INDEX Aerotech, Inc. 25 Allied Electronics Inc. 1 + 13 AutomationDirect 2 Beckhoff Canada 5 Carlo Gavazzi (Canada) Inc. 7 Eaton Canada 11 Encoder Products Company 6 EPLAN Software & Services LLC 27

Murrelektronik Canada Pilz Automation Safety Ringball Corporation SCHUNK Intec Corp. SEW Eurodrive Siemens Canada Ltd. TURCK Chartwell Canada Inc.

3 23 21 31 9 32 19

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MA’s Technology Handbooks are a series of digital magazines that focus on a single product category within Canada’s manufacturing industry. Posted on MA’s website as an interactive flip-style magazine, our Technology Handbooks provide specific market and product information, as well as trends within that specific product category, to machine builders, component manufacturers, end-users and system integrators.

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WHAT MA PUBLISHED IN...

BACKSTORY

2001 “Laser scanner frees more time to make sheet metal parts.” 2004 “We were at the point in our operation where we were successfully producing quality products, yet we didn’t have a way to measure efficiency.”

1998 “Is it any wonder manufacturers are demanding integration, portability and scalability for their HMI systems?”

2008 “An old and new control system share information and save $21 million in lost production value.”

2011 “CB Engineering saves $250,000 annually and reduces operating expenses by moving to the Cloud.”

2010

“Think. Plan. Do. Measure what gets done.”

ost manufacturers consider this a statement they can relate to, especially the last two components: do and measure what gets done. The biggest opportunity for improvement however, is through the first two components: thinking and planning. Unfortunately, there’s not as much technology readily available for this as there is for the doing and the measuring parts. For the doing part, manufacturers make significant investments to replace and upgrade our machines. For the measuring part, we make investments in ERP systems, and to a lesser extent, in machine monitoring systems. These investments make sense to manufacturers because we realize the importance of making data-driven decisions, and that we can’t improve

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what we don’t measure. However, frequently these systems fail to deliver the benefits and advantages we need to compete, or fail to deliver a return on their (often significant) investment. Their potential benefits are often limited by one of two beliefs: 1) the thinking and planning have already been done, or 2) it is someone else’s responsibility to do the thinking and planning. Many plants have planning and modelling tools, but they are only for select processes (running CNC simulations for instance) or select individuals (the general manager or production scheduler). But efficiency and effectiveness are not the same thing, and to run a plant effectively,

“Software for the future: New technologies will be driven by new software, so be prepared.” 2014 “The reality is that using paper or collating numbers on an Excel spreadsheet to collect performance information will always leave factories with data that is subjective and out of date.”

you need everyone to think and plan. If you run a part on the wrong machine while running that machine efficiently, you are really just wasting time efficiently. If one final assembly requires 20 individual pieces to be machined and 19 of them are done in time, you are not 95 per cent on time, you are 100 per cent late. Manufacturers may be sensitive to these kinds of conditions, but yet they continue to experience them routinely. Why? Because they make it only one or two peoples’ responsibility to think and plan, when in fact it should be a responsibility shared by many more. Plant-level software solutions need to do more than schedule production or monitor machines; they need to engage everyone involved in the Think. Plan. Do. Measure what gets done. process. | MA

Paul Hogendoorn is president and co-founder of FreePoint Technologies (www.getfreepoint. com), a company dedicated to developing effective and engaging IT solutions for the factory floor. May 2017 · MANUFACTURING AUTOMATION

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