2022 Advanced Manufacturing Expo Magazine & Program by MiBiz

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REDEFINING GRAVITY READ ABOUT IT ON PAGE 4

6 Q&A: MARK ERMATINGER

AME founder Mark Ermatinger took a few moments to share his thoughts on what attendees and exhibitors can expect to see at this year’s expo.

8 ESCAPING DATA ISLAND

How manufacturers are going beyond data collection to drive operational improvements.

OVER: AMRs COMING TO A FACTORY 10 MOVE NEAR YOU

Michigan companies are saving time and money by investing in automation to streamline certain processes inside factories.

DOWN: HOW THE INTERNET OF THINGS IS 12 BEARING REDUCING FACTORY DOWNTIME

All manufacturers have been there: A ball bearing in a gearbox suddenly fails and production comes to a standstill, with products sitting on the line, workers left with nothing to do, and thousands of dollars wasted until a replacement is made.

DONE RIGHT: TMS OFFERS 14 DATA MANUFACTURERS REDUCED INVENTORY, COSTS

Tool management systems (TMS) are changing the datamanagement game for manufacturers, largely because they’re so useful at reducing costs, improving uptime and increasing productivity.

CASE STUDIES ROUND UP: SAVING MANUFACTURERS TIME AND MONEY

A round up of a few case studies from current AME exhibitors who have saved their clients both time and money.

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SHOW INFORMATION CREDIT: REDDOT MEDIA & DRIFT LIMITS

In an age where groundbreaking technology is increasingly commonplace, Gravity’s jet suit inspires rare awe.

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ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

RE-DEFINING

GRAVITY In an age where groundbreaking technology is increasingly commonplace, Gravity’s jet suit inspires rare awe.

he Advanced Manufacturing Expo 2022 will bring visitors face to face with the latest in manufacturing innovation. Gear sensors that can predict a failing bearing, AI that can coordinate the movements of mobile industrial robots, and the world’s first jet suit, courtesy of UK-based Gravity Industries. Yes, you read that right: an actual jet suit. And it will soar through downtown Grand Rapids, Michigan on August 11th as part of the show. In an age where groundbreaking technology is increasingly commonplace, Gravity’s jet suit inspires rare awe. Maybe it’s because we’ve been dreaming about individual flight for three-quarters of a century — from 1950sera film reels promising jetpacks in every household to ‘60s era cartoons like “Jonny Quest” where jetpacks and bazookas were the answer to most any problem, and all the way up to “Iron Man 3” in 2013. Now, something that humanity has been collectively dreaming of for generations is finally here. When Gravity Founder and Chief Test Pilot Richard Browning talks about his invention, it is clear that within him is an enthusiasm that resides within few of us, but has the potential to change all of us. Before founding Gravity in 2017, Browning was in the Royal Marine Reserves for six years and an oil trader for 16 years. Aviation is in his blood — his father was an aeronautical engineer and maverick inventor; one grandfather was a chief executive at a helicopter company, and the other

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

was a fighter pilot in WWII. When Browning was 15, his father took his own life. “It left a bit of ambition in me to pursue crazy ideas like he did, but also led me to play it safe after seeing how bad things can get when those ventures don’t work out,” Browning said in an interview in advance of the 2022 Advanced Manufacturing Expo. Browning’s military experience laid the foundation for his sincere belief that the human mind and body can be trained to exceed preconceived expectations. “The Royal Marines taught me that it’s amazing what you can train your mind and body to do if you put your mind to it,” Browning said.

CREDIT: TOM JACKSON PHOTOGRAPHY

gas turbines. Video footage shows him in various locations testing out the idea. First, on a country road with one micro-gas turbine strapped to his arm. Then in a field, with two micro-gas turbines “There is part of your strapped to his arms and brain that looks at it and wired to a backpack as thinks it is fake,” he said, he jumps, aiming the tur“People sometimes are in bines at the grass below. tears because it is hard Then, in a farm yard, with to rationalize and digest four gas turbines on his it — it’s an extraordinary arms; then six on his experience. But, finally, when arms, two on his legs, you are in the suit, it’s the and finally, a few incredmost powerful yet gentle ible seconds of flight.

thing you will ever feel.”

“It felt amazing and relieving to achieve it,” Browning said. “There were many moments of falling over and breaking gear and ‘Damnit, I know we can do this.’ It was a dawning of ‘If it works this well now, imagine how well it is going to work when we properly iron out all of the things buzzing through my brain that I knew we could improve.’”

—Gravity Founder Richard Browning

I n 2 01 6 , B r ow n i n g described having “the latest in a long line of unusual ideas” and what would eventually become the Jet Suit. “Could you reimagine human flight for no business reasons whatsoever?” he said. “How far could you get with the seemingly mad idea of the human becoming the flight vehicle? It is just a question of how to connect the human body and the human balance system with that form of propulsion.” The concept is surprisingly simple: replace a solid surface with a brief form of propulsion. Browning began playing around with small

In 2017, on his way to the TEDXVancouver event, Browning stopped in California to demonstrate his jet suit to father-son billionaire venture capitalists Adam and Tim Draper. He left with a contract for a $650,000 investment written on a $100 bill. VISIT ADVANCEDMANUFACTURINGEXPO.COM

Today, Gravity’s Jet Suit is made of carbon fiber, aluminum and 3D printed polypropylene. With five turbines, it delivers over 1000 horsepower and can achieve speeds more than 50 mph and flight times of 1-4 minutes. Browning says the suit is made possible by the sophisticated small gas turbines developed by aviation enthusiasts unrestricted by commercial enterprise and regulatory hoops. “The community working on these, to put it very simply, are retirees from the aviation world,” Browning explained. “They spent their careers working on things that take 15 years to get approved. But in model aviation, no one cares; you can build your little jet engine, crash it and improve it.” Gravity’s equipment is 3D printed, allowing for lighting-fast testing and problem-solving. With just a week between designing and having gear in hand, the iteration pace is astounding. “Large companies spend months planning, designing and testing,” Browning said. “At the end of the year, they may have done 2-3 versions. We can do 2-3 versions in a fortnight.” Browning and his team at Gravity Industries enthusiastically embrace battery and motor technology advances to continue improving the Jet Suit. In 2021, Gravity Industries

WATCH IT FREE GRAVITY TAKES FLIGHT Flying Over the Grand River LIVE Demonstration: Thursday, August 11, 4 p.m. Keynote Presentation: Friday, August 12, 10 a.m. debuted its eSuit concept, an electric jet suit powered by high-discharge LiPo batteries. Browning describes flying in the Jet Suit as surreal yet natural. “Every time you fly, it really feels like that dream you have where you are running, then you step, and you fly wherever your mind takes you,” he said. “It is as intuitive as running or walking.” Gravity Industries has executed more than 150 flight events across 35 countries. The Jet Suit has been successfully tested in the military and search-and-rescue applications. In 2020, Gravity was set to premiere the Jet Suit Racing League in Bermuda; however, plans were halted by the COVID-19 pandemic. In November 2019, Browning broke his original Guinness World Record for Jet Suit speed, reaching an incredible 85.06 mph.

For Browning, watching people experience the Jet Suit for the first time never gets old. “There is part of your brain that looks at it and thinks it is fake,” he said, “People sometimes are in tears because it is hard to rationalize and digest it — it’s an extraordinary experience. But, finally, when you are in the suit, it’s the most powerful yet gentle thing you will ever feel.” While Gravity Industries has achieved what many thought undoable, Browning and his team are committed to the journey of reimagining human flight and improving on the Jet Suit. To inspire others to allow themselves to think and dream without boundaries, Browning advises to put it through the reputational, financial, and safety tests. If it fails, will you get in trouble? Will it damage your finances? Will anyone get hurt? If it passes, test it cheaply and play with it. The first version of the Jet Suit was made with a child backpack carrier and a climbing harness. “Children don’t have the problem of limited imagination,” Browning said, “They don’t worry that it won’t make money; they just play. In innovation, you need to sit there like a child and imagine something stupid and mad. “ n

PHOTO COURTESY GRAVITY INDUSTRIES VISIT ADVANCEDMANUFACTURINGEXPO.COM

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

Q&A

MARK ERMATINGER Founder, Advanced Manufacturing Expo CEO, Industrial Control Back and larger than ever, the 2022 Advanced Manufacturing Expo in Grand Rapids has truly outstripped its humble origins as a niche event, attracting attendees and companies from across the globe. This year’s expo will feature more vendors than ever, spanning the entire main exhibit hall of the DeVos Place. The event also will showcase Gravity Industries, the U.K.-based creator of fully functional jet suits. AME founder Mark Ermatinger took a few moments to share his thoughts on what attendees and exhibitors can expect to see at this year’s expo. He also talked about how companies entering the expo are navigating the current business climate and what technologies he sees as paving the way for the future of manufacturing.

What sets this year’s show apart from previous year’s events? The show is bigger. There is 30 percent more vendor space than last year. It’s gone from 120,000-square feet to 180,000-square feet. We rented the entire main exhibit hall of the DeVos Place. We’re investing in Michigan. The level of commitment from the exhibitors has been astonishing, too. They’ve stepped to the plate and we’re pretty much sold out in most of the halls. You’re going to see a lot more exhibitors than in years past.

In terms of exhibitors, are they bringing more sophisticated technologies and displays? Last year, the Metalworking Hall did really well with lots of vendors bringing in CNC machines and making chips on the floor with

PHOTO: KATY BATDORFF

They’re going to talk about the technology (they use), what it took

robotic tending. A lot of that is coming back, but you’re seeing

to achieve their dream and the hurdles they had to overcome.

larger displays. People are talking about bringing in semi-trucks

They’re all about disruptive technology and so is the Advanced

to have demonstrations. The booth space is also getting bigger. I

Manufacturing Expo. That’s why we feel they’re a good fit for the

have a lot of exhibitors who would normally be in a 10-foot-by-10-

show. Honestly, we’re sticking our necks out here a bit by bring-

foot space that are now in 20-foot-by-20-foot spaces and they’re

ing them to the expo. A company like Gravity wouldn’t typically

bringing in a lot more equipment because they have so much

come to Grand Rapids. They typically are going to do Paris or

more space.

Los Angeles or another major city. The fact that we’ve convinced

What does bringing in a company like Gravity as the keynote do for the expo?

them to come to Grand Rapids is really a testament to what we’re

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

trying to do. VISIT ADVANCEDMANUFACTURINGEXPO.COM

What’s on the minds of exhibitors as they enter the show, given current industry trends? We’re seeing people reinventing themselves all the time because they have to. Before they had the luxury of hiring summer students or could otherwise find people when they got busy. That’s just gone. It doesn’t matter who you are anymore. You have to reinvent the way you do business and your procedures. Some of the speakers we have will help address these trends.

What areas of emerging technology are standing out this year?

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There are a couple different areas. The more easy solutions are collecting data and responding to that data. That’s the first step. Then you’re getting into the digital twin, especially in the Metalworking Hall. That’s basically your part in a point cloud. As you’re going along manufacturing, you’re working with basically a digital clone so that you can make design changes on the fly. Next, I would say AI. Artificial intelligence was just a buzzword a couple of years ago. Now, we’re seeing a lot of real products that include the technology. It’s definitely here and it’s robust. At the show, we have a machine-vision quality-control camera that has AI on it and you don’t even need to program that camera. Traditionally, it would take months or years of training to set up a machinevision camera. With this new AI camera, you can deploy it in less than an hour with no training. That’s just unheard of. There’s also no server involved, it’s just browser-based software. That’s the other thing: You used to have to download all your software to run different things. Now it’s right on the web browser built onto the unit, so you can just log on with your phone or PC and just start programming.

What personally are you most excited about for the show? I think this show turned the corner last year, and attendees are going to see a lot more people coming from further distances, whether that’s Europe, Texas or California. The level of networking and knowledge

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ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

ESCAPING DATA ISLAND How manufacturers are going beyond data collection to drive operational improvements

he proliferation of sensors, programmable logic controllers (PLCs) and countless other advancements in Internet of Things technologies has created a massive trove of data for manufacturers to access.

Control. “I’m doing something that’s adding no value to my organization and adding no value to the customer. If I’m just collecting data and not using it to impact my business, then I’m wasting my time and resources.

However, without the proper tools, systems and training in place, this wealth of information can largely go untapped, creating a drag on an organization rather than improving efficiencies, increasing quality and driving value.

“You don’t realize the impact or ROI on these investments until you use the data to make changes in your organization.”

“You can collect all the data in the world, but unless you’re using that data, it’s overprocessing, as they would say in manufacturing,” said Michael McGray, a senior sales engineer with Zeeland-based Industrial

“You can collect all the data in the world, but unless you’re using that data, it’s overprocessing … (You’re) doing something that’s adding no value to my organization and adding no value to the customer.” —Michael McGray, senior sales engineer at Industrial Control 8

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

Data collection is nothing new. Supervisory Control and Data Acquisition (SCADA) systems have been around for decades. However, in today’s technically driven manufacturing environment, it’s no longer enough to simply collect data. SCADA has since evolved into a larger umbrella including data storage, visualization and analysis in which myriad tools, information systems and software are used to drive process improvements on the shop floor. Yet many manufacturers are “deadheading” the data they already collect, leaving it on their various machines or stuck in “shadow” databases they don’t readily access, McGray said. In his work, McGray points to numerous examples where an operator manually records the number of pieces a machine is producing. A supervisor then comes around, evaluates the production rate and determines if the operator and machine are on task. This amounts to a manual

intervention, ultimately decreasing efficiency, according to McGray. The machine’s sensors are already conducting a piece count along with other key parameters such as the RPM of the tool. This data should then be exported to a database where it can be viewed immediately by the operator and analyzed and benchmarked later by production managers and other executives. “Unless people are looking at the data, it’s still not helping at all and you’re still going to have the same old problems,” McGray said. “That’s what this has really been about: getting this data off these islands and into an environment that brings transparency to it.”

IMPLEMENTATION REALITIES In practice, expanding beyond data collection into storage, visualization and analysis can prove challenging for manufacturers, particularly smaller and mid-size companies that may lack the resources and expertise to properly implement the systems. One of the primary challenges comes from making all the different technologies — sensors, PLCs, robotics, machines and other tech — interface in a cohesive manner. These technologies may all operate under different industrial protocols or “languages” and require third-party tools and software to translate them through a company’s ERP or MES system, according to Gray. Once all the different pieces of technology around the shop floor are communicating in the same language, manufacturers need to store that data in a database such as SQL or Oracle. From there, they should deploy a data visualization tool, like PowerBi, to properly analyze and act on the data. The issue is that these are often complex and expensive systems, outside the budgets for many small and mid-size manufacturers. When helping manufacturers implement these systems, McGray likes to begin VISIT ADVANCEDMANUFACTURINGEXPO.COM

“No one wants to be late,” McGray said. “If data collection can help you accomplish being on time, most people aren’t going to fight you. The problem comes in the implementation of these systems and having the capital to go and find the right integrator to connect your equipment, implement the correct information systems and train your personnel on how to become database decision makers instead of being reactive.”

TWO WAYS TO LEARN MORE ABOUT “OPEN CONTROLS” n Senior Engineers from Wago, Inc. will be speaking about how to capture, display, and move data on Thursday, 9 AM in the speaker Automation Room #1 (see page 16) n Michigan Manufacturing Technology Center (MMTC) has its Smart Technology Zone cul-de-sac of exhibitors and speakers about Industry 4.0 by addressing prominent pain points, in many cases starting with on-time delivery. McGray analyzes the operation at the cell level to determine which specific operation kicks off the delay. Then he helps facilitate data collection and analysis on those operations so management has a clear picture of what is happening at any moment.

ACCELERATING ADOPTION As data collection, storage and analysis becomes a larger part of the manufacturing ecosystem, emerging technologies are making implementing the comprehensive systems easier. McGray specifically points to MachineMetrics and Freepoint, as examples of new tools that are agnostic of hardware. These platforms allow companies to

log into and configure devices remotely and use third-party connector tools to communicate with all of the equipment on the plant floor. The data are then automatically uploaded to the cloud, where the tool provides robust data analytics capabilities and the ability to contextualize the data in one platform, McGray said. Advancements in technology will likely continue to drive down the costs and barriers of entry associated with data collection, storage and analysis systems. Ultimately, all of the base technology and concepts already exist; it’s a matter of companies finding the technology that fits their budget and use case. “Data collection, storage, analytics and visualization are the core components and that’s what it’s really about,” McGray said. “Everything else is about innovation.” n

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never down at the factory.” LeMaire said an AMR can cost as much as a hi-lo, but “you also get additional savings from the labor needed to operate that equipment.” “A lot of companies deal with moving parts — from the raw goods stage to finished goods — which may be just a few boxes of product leaving,” he said. “Electrical components, metal machine parts, household goods, and consumer goods are all great opportunities to be able to move with AGVs.”

MOVE OVER

AMRs coming to a factory near you

very few minutes, an autonomous mobile robot (AMR) removes a full cart of partially finished goods and replaces it with an empty cart. This, of course, is without the need for humans. Nowadays, Michigan companies are saving time and money by investing in automation to streamline certain processes inside factories. It can be as simple as picking up trash in a plant or as complex as a pharmaceutical company moving product between its plasticinjection molding machines and assembly line. According to Dennis LeMaire, a sales engineer 10

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

for Zeeland-based Industrial Control, all industries — from retail to healthcare — are analyzing processes to gain efficiencies, avoid production bottlenecks, and stay competitive. By purchasing robots, companies can free up human workers for other tasks and eliminate project downtime. “Where I see automated guided vehicles (AGVs) and AMRs really coming into play are companies continuing to refine their processes,” LeMaire said. “It just makes sense to pull that labor out and have a consistent way of being able to deliver products from point A to B.” Unlike AGVs which navigate with magnetics strips embedded in the floor, AMRs are guided

via stored floor maps and are directed from a Fleet Server or the company’s ERP system, whic communicates to the robots using a wireless network. Lidar, ultrasonic sensors, and 3-D cameras allow the robots to adapt to changing environments and production requirements, all with modifications to their software. “So if you’ve got a robot that needs charging, or if there’s downtime, you can program in opportunity charging,” said LeMaire, noting AMRs are a form of automated guided vehicles. “The goal is to be able to have enough robots and capacity to move the product where you need to, including built-in charging time, so that you’re actually

Those opportunities are why AMR demand continues to rise, LeMaire said. According to a market intel report, the segment is expected to reach $22.15 billion by 2030, up from $1.61 billion in 2021. “When companies adopt their first robot, a lot of times they go from one (or) two to five to 10 robots,” LeMaire said. “That number rises exponentially because they’re able to see what that benefit is on their floor.” Ben Greve, senior sales engineer for Industrial Control, said there’s a ubiquitous need for this technology. “Anybody who’s moving stuff is going to need this technology,” Greve said. “With the labor shortage, if (employers) can spend $40,000 to $60,000 on an AMR and repurpose one or two associates for higher-value tasks, that’s a no-brainer right now.” A customer of Greve’s recently purchased 45 robots to address some of those concerns. This customer built up his or her VISIT ADVANCEDMANUFACTURINGEXPO.COM

fleet of robots over the past three years.

“Where I see (automated guided vehicles) and AMRs really coming into play are companies continuing to refine their processes. It just makes sense to pull that labor out and have a consistent way of being able to deliver products from point A to B.”

It’s the new normal, say industry insiders, who note menial warehouse and inventory tasks can now be handled by the AMRs.

“I have one customer that uses these for a ‘milk run,’ where they’re taking parts that are ready to be put “As the environinto assemblies, ment changes —Dennis LeMaire, sales engiand instead of where skids neer for Industrial Control a person pushcome into play, ing a cart around and the prodand unloading the parts, the AMR uct is moved around, the robots makes the run,” Greve said. “The will read off of those situations person is freed up to do someand revise its route so that it can thing else.” optimize how it gets through the plan,” LeMaire said. “It has the Greve said customers also ask ability to look out in front of itself him if the robots can be used to … 50 feet. It can recalculate as pick up trash or scrap. things are coming toward it.” “It’s bringing materials to lines or Companies use this to their taking materials from lines,” he advantage by taking the human said. factor out of driving hi-los. “That’s helped alleviate staffing According to LeMaire, the traceshortages. Now you have a robot ability of where and how the that’s doing the job of a person product is moved is all tied to and frees them up to do somethe management system, which thing higher value add.” can be accessed via a Wi-Fi connection.

LABOR, LABOR, LABOR AMRs can independently move around obstacles to fulfill tasks, ensuring material flow stays on schedule. LeMaire remembers a robot demo when roughly 30 people moved through halls, putting their feet in front of the robots to mess up their routes. But “the robots had blinders on,” he said. “This was an application where at any point, a portion of that labor force was bringing small orders from one end of the building to the other. The robots did it seamlessly.” VISIT ADVANCEDMANUFACTURINGEXPO.COM

“And this technology has all happened in the last four or five years,” LeMaire said. “I’m looking forward to seeing the advancements in this technology. Highbay storage is a situation that’s going to be out there in the market.” While contemplating the future of warehouse technology, LeMaire sees AMR possibilities outside the four factory walls. “I mean, can you really see someone driving around on a golf cart moving goods?” LeMaire asked. “Probably not.” n

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BEARING DOWN How The Internet of Things is Reducing Factory Downtime

ll manufacturers have been there: A ball bearing in a gearbox suddenly fails and production comes to a standstill, with products sitting on the line, workers left with nothing to do, and thousands of dollars wasted until a replacement is made.

Jack Gilmer, West Michigan territory manager for Dodge Industrial, refers to the Smart Sensors as “like a FitBit” and emphasizes the power of the data collection.

“Downtime is the bane of every manufacturing plant in the world,” said Ben Shine, sales account manager at the Grand Rapids branch of Motion, a subsidiary of Genuine Parts Co. “Businesses have historically accepted that as a part of making product.”

“As you are collecting trending data, each bearing creates its own signature,” Gilmer said. “Every bearing doesn’t operate at the same temperature and vibration, depending on where it is installed. Over time, it creates a baseline.”

The average manufacturer deals with 800 hours of downtime a year, with costs ranging anywhere from $500 per hour into the thousands, depending on the products on the line. According to a study conducted by MIT, an estimated $240 billion is lost annually in industries across the United States because of downtime for repairs on failed manufacturing equipment. Half of those failures are due to improper bearing maintenance.

Each company that uses Smart Sensors owns its data outright, and data are encrypted as recommended by the National Institute of Standards and Technology. Personnel can view the data on a smartphone, tablet or computer.

Now, thanks to Smart Sensors, downtime may be a thing of the past. Dodge Industrial, a leading manufacturer of mounted bearings, enclosed gearing, and power transmission products, worked with ABB Group to develop the Dodge Smart Sensor five years ago. The sensors are small, about 3-inches tall, and fit on a variety of gearboxes and mounted bearings. They monitor assets for temperature and vibration, aggregating real-time data that is pushed through a gateway via Bluetooth into the cloud and into an app, which alerts users to anomalies that indicate a need for maintenance before a failure is imminent. One gateway can collect data from 50 sensors on a shop floor. This interconnectivity is called the Industrial Internet of Things, and it’s revolutionizing the shop floor by giving machines a means to “talk” to workers by letting them know when a critical component is on the verge of failing. 12

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

Mock-up dashboards from Dodge show what looks like an EKG reading as the sensors track the temperature and vibration data. The interface is intuitive and designed for ease of use. It communicates the health of a part with the classic traffic light sysMANUFACTURING tem: Green for tip-top shape, yellow to alert DOWNTIME BY something may be amiss, and red to alert THE NUMBERS an impending failure. Systems also can use advanced algorithms to direct maintenance endeavors and establish protocols.

800

is the average number of hours a manufacturer deals with each year.

$500

is the hourly cost of downtime for manufacturers

$240B

lost annually across the U.S. because of manufacturing downtime

50%

of manufacturing failures due to improper bearing maintenance

Motion distributes replacement components for machines as well as the Dodge Smart Sensors. As such, Shine is familiar with the pain a sudden bearing failure can cause a company. “A lot of manufacturing plants, when they have a failure, it is a critical failure,” he said. “Everything stops, the line shuts down. You may have product on the line that isn’t salvageable. You may have a product that has a dwell or set time. It’s extremely expensive.” Manufacturers typically perform maintenance on a schedule, but when a bearing VISIT ADVANCEDMANUFACTURINGEXPO.COM

fails, it fails suddenly and needs immediate attention, or reactionary maintenance. With minimal installation time, Smart Sensors provide unprecedented opportunities for monitoring machine health while increasing effectiveness and improving safety and productivity on the shop floor. “You can do a planned outage to replace or repair that part, which doesn’t disrupt production,” Gilmer said. “Safety-wise, many of these bearings are in the bowels of the process and are not easily reachable, so it is collecting data from these hard-to-reach areas. Also, when something fails critically, it may take out other pieces of equipment.” Additionally, as preventive maintenance is currently performed, workers use their best-informed guess as to when a part needs to be replaced, potentially replacing parts that don’t need it. “With predictive maintenance driven by the sensors, you can run a bearing for the entire life of the product, which adds up to huge savings,” Shine said. While the Smart Sensors need to prevent just one incident of factory downtime for customers to recoup their investment, many manufacturers consider the initial cost as prohibitive, Shine added. “(Smart Sensors) are now much more consumer-friendly, and now we are in a world where sensors are far less than $1,000 a sensor,” Shine said. “They just need to prevent one downtime and it pays for itself. Like anything else, the more people use it, the more they buy, and the price drops.” For Shine, the capability of Smart Sensors signals a data-driven glimpse into the shop floor of the future, where sensors alert workers to bins being low on raw materials or signal when shipping areas need to be clear before production continues. “All of these mundane tasks can be automated and monitored by technology,” Shine said. Today, Motion is adapting quickly to provide customers with other smart products, such as pneumatic air cylinders that are powered by electronic actuators, allowing for precise control. “Say you are gluing a box. With an electric actuator, you can finitely control it to deposit just the right amount of glue,” Shine said. “You’re saving money and getting a much better product.” Gilmer notes that as the Industrial Internet of Things moves further and further into the shop floor, the need for laborers will diminish in place of a growing need for technicians. “They have to be able to trend data and set up technology,” he said. “It is all going to be on computers, and we train people ourselves once they come on board.” Shine says that adaptation to new technology on the shop floor will pick up as manufacturers realize a future free of downtime. “We are creatures of habit, and it requires a shift in thinking,” Shine said, “but the cost savings are really a no-brainer.” n VISIT ADVANCEDMANUFACTURINGEXPO.COM

To be your voice, we must hear your voice. For 120 years, the Michigan Manufacturers Association (MMA) has been a unifying champion of an industry in constant evolution and growth. Our mission to the industry is clear: to hear your voice, to unify your voice, to amplify your voice and to be your voice. Your company can’t afford to not be a member. Join the only association dedicated solely to manufacturers. Learn more at mimfg.org. Special Offer Join MMA at mimfg.org with code EXPO2022 to receive 20% off your first year’s dues investment.

INTEGRATES WITH SOLIDWORKS AND PDM

BE ACCURATE AND ON TIME FROM

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DELIVERY BOOTH # 914 ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

DATA DONE RIGHT

TMS offers manufacturers reduced inventory, costs

ool management systems (TMS) are changing the data-management game for manufacturers, largely because they’re so useful at reducing costs, improving uptime and increasing productivity.

The slow uptake can be expected with any new technology, Hendricks added. “It’s quite an endeavor to make the commitment financially and, more importantly, the implementation and buy-in from the entire organization,” he said.

Paul Hendricks, CEO of Grand Rapids-based Creston Industrial Sales Inc., said TMS checks many boxes for manufacturers. Implementing the systems can also help companies reduce tooling SKUs, inventory, and costs.

SELLING TMS TO OTHERS

Hendricks points to the 30-20-10 TMS goal for businesses. For example, if you have 10,000 different tooling SKUs, a TMS should be able to reduce that number by 30 percent, inventory by 20 percent, and overall costs by 10 percent. “If you’re managing fewer items, you’re going to be more efficient as an end user,” Hendricks said. “Carrying inventory and managing it can be cumbersome. Implementing 30-20-10 would be a good target for why a company might want to invest in a good TMS system. Tooling management can also help with the interconnectivity of all your systems and the improvement of your design and simulation processes.” TMS serves as a database for accurate tool information. Hendricks’ Creston Industrial “wholeheartedly” embraces the technology and encourages other businesses to join the datamanagement movement. “Like any industry, digitization and technology improvements are happening; our industry is no exception,” Hendricks said. “A good tool-management system can really help the end user and the manufacturer become more efficient and increase productivity in their facilities.”

“Carrying inventory and managing it can be cumbersome. Implementing 30-20-10 would be a good target for why a company might want to invest in a good TMS system. Tooling management can also help with the interconnectivity of all your systems and the improvement of your design and simulation processes.” —Paul Hendricks, CEO of Creston Industrial Sales Inc. 14

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

“Once they have found the item that they’re looking for, they can easily download the data of the tooling components into their CAM system or their TMS system,” he said. “The adoption rate of a full-blown installed TMS is still growing, but still a majority of our customers are not doing this.”

Companies want higher productivity rates while slimming down on material use. Using databases with accurate information can make a huge difference, said David Darling, chief strategy officer for CimSource North America, a global company that provides product databases. Manufacturers’ adoption of TMS comes as part of a larger revolution. In a survey of executives, management consulting firm McKinsey and Co. found that companies must change their operational models and organizational structures to “reflect the new environment so that organizations continue to reap rewards from their technology investments.” “At the same time, these management systems can take advantage of new technologies beyond the basic desktop productivity tools available to workers,” the authors at McKinsey wrote in the June 21 report. “While automation software was expensive and out of reach for many organizations a decade ago, it is now affordable and scalable for businesses of all sizes. Digital tools have now reached a level of maturity that is ready for prime time and at-scale deployment.” Creston Industrial understands this tech sea change and recently partnered with Germanybased CimSource to build-out its engineer and buyer portals. CimSource North America uses an international tool standard called Standard Open Base (StOB) to ensure tools are all made to specification. That information is fed into a tool management system so tools can be delivered on time. In the last six months, the company has on-boarded three large American toolmakers. According to Hendricks, Creston Industrial’s updated portals incorporate advanced searching capabilities for users for various tools, allowing more flexibility.

“This industry has bought tools the same way since, essentially, the beginning of time,” Darling said. “When you go to Amazon and you have to find a pair of pants, you might sort by a color or an inseam length, but that’s oftentimes as complex as it’s going to get. Whereas with our tools, there could be 100 to 150 valid parameters, any one of which might be the one that’s going to make that the right tool for you.” Because a filtering tool system like this didn’t exist, CimSource created search portals for Creston Industrial that would cater to people who need to replenish old tools (a buyer’s portal) to those trying to discover something new for an application (an engineer’s portal). “It’s taking what CimSource already knows as it relates to data and structure for the engineering of these types of things and marrying it with the e-commerce capabilities,” Darling said. “You can go in and use that high-end and detailed parameter-based search for application-based search features and find the tool that you’re looking for.” The best way to sell TMS and similar technologies to companies is to show them, Darling added. While companies may have completed tasks the same way for years, most accept the inevitability of change. “Once you see it, it’s kind of hard to unsee it,” Darling said. “From my perspective, it’s helping these vendors find standard formats, converting what they have, filling in the gaps for what they don’t have, and getting it to the end users when they want it in the format they want it.” n VISIT ADVANCEDMANUFACTURINGEXPO.COM

States lose an estimated $240 billion annually because of downtime for repairs on failed manufacturing equipment. Half of those failures are due to improper bearing maintenance. “Downtime is the bane of every manufacturing plant in the world,’ said Ben Shine, sales account manager at the Grand Rapids branch of Motion, a subsidiary of Genuine Parts Co. “Businesses have historically accepted that as a part of making product.” To reduce and eliminate that waste, Jack Gilmer, West Michigan territory manager for Dodge Industrial, says companies can turn to Smart Sensors for help.

CASE STUDIES ROUND UP Saving Manufacturers Time and Money Ahhh, the Advanced Manufacturing Expo. In the past, I would do two laps of the halls: Once to fulfill that childlike wonder of all things manufacturing — as a kid who grew up in a family manufacturing business, I just can’t escape my love for all built things and human ingenuity to create our hearts’ desires — and a second time with my owner hat on. As a former economic developer functioning in a consultative role, I used to (and sometimes still) get asked, “Bottom line: What can I invest in that is going to save me time and money?” To answer that question, here is a round up of a few case studies from current AME exhibitors who have saved their clients both time and money. — Justine Burdette, associate publisher, MiBiz

On Time Delivery Issues Solved Supervisory Control and Data Acquisition (SCADA) protocols have been around for decades, but today have evolved into a larger umbrella of coordinated systems including: Analysis, where a third party software translates between all the various industrial protocols or “languages;”

the delay, whether that’s machining, deburring or some other process. Then he leverages SCADA and a host of other tools to provide management with a clear picture of what is happening at any given moment. At the end of the day, McGray is moving manufacturing leaders and supervisors from being reactive to database decision makers, saving companies both time and money.

AMRs Move Labor to More Value-Added Tasks Every manufacturer needs to move stuff, whether it’s raw materials, finished goods, work in process, or trash and recycling. In the past, this was done by forklifts, water spiders, and a variety of material handlers. These days, autonomous mobile robots (AMRs), which cost about as much as a forklift but have no need for a driver, are taking over these roles and freeing up labor to do more value-added tasks. Ben Greve, senior sales engineer for Industrial Control, said there’s a ubiquitous need for this technology.

Data storage, where all information is moved into company’s ERP or MES system; and

“Anybody who’s moving stuff is going to need this technology,” Greve said. “With the labor shortage, if (employers) can spend $40,000 to $60,000 on an AMR and repurpose one or two associates for higher-value tasks, that’s a no-brainer right now.”

Visualization, where something similar to PowerBi is used to properly analyze and act on the data.

Sensors Reduce Downtime

Michael McGray, a senior sales engineer with Zeeland-based Industrial Control, likes to address prominent pain points like on-time delivery. McGray reviews the operation at the cell level to determine which specific operation kicks off

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“It’s predictive maintenance, like the Smart Sensors, that are really saving customers time and money, ‘’ he said. “Especially with our customers in the food industry, we have seen more and more of a tendency for stainless steel components — gearboxes and bearings that don’t corrode.”

Electric Actuators Dial In the Savings According to Ben Shine at Motion Industries, “More and more people are starting to use electric actuators. For instance, if you need to clamp something together using pneumatic power, you may have to use four different setups for different-sized items. If you run an electric actuator, you can just use a button to tell it how far to go out and how much force to put on the part, so the same piece of equipment can handle different widths and different product dimensions. That is a huge cost and time savings.”

Downtime Codes and Root Cause Analysis Companies often do not track downcodes, or reasons why a machine has stopped operation — for example, a tool broke, a maintenance issue occurred or the operator ran out of material. In the past, this made sense: The most important thing when a machine stopped running was to get it back operating. However, manufacturers today need to get that machine operating again and do a root cause analysis on why it stopped in the first place. But ask an operator about the four-hour downtime they had last week and the chances are they’re not going to remember sufficient information to make informed decisions about how to prevent this from happening again in the future. New data collection systems are connected to sensors and allow operators to enter downcode or scrap code reasons at the time of failure. These can then be organized and run through a root-cause analysis to find the reason for the downtime. After this, companies can take steps to prevent downtime in the future. n

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

SPEAKER/BREAKOUT ROOM AGENDAS

AUTOMATION ROOM 1

METALWORKING ROOM 1

9:00 AM - 10:00 AM

THE POWER OF OPEN SOURCE IN IIOT - HOW INDEPENDENT CREATORS ARE BUILDING INDUSTRY 4.0 Speaker: Jesse Cox Presented by: WAGO

WOMEN IN MANUFACTURING PANEL DISCUSSION Speaker: Danielle Schneider Exhibitor: Women in Manufacturing

10:30 AM - 11:30 AM TROUBLESHOOTING CRITICAL INDUSTRIAL ETHERNET NETWORKS Speaker: Alex Guerin Presented by: Softing Inc.

MARKETING DOESN’T HAVE TO SUCK // 5 STUPID SIMPLE STEPS TO MAGNETIZE YOUR TARGET AUDIENCE Speaker: Emily Wilkins Exhibitor: Marketing Metal

12:00 PM - 1:00 PM

IDENTIFYING VALUE IN DECOMMISSIONED AND SCRAP MACHINERY Speaker: Dale Watkoski Presented by: USA Industrial Scrap

1:30 PM - 2:30 PM CTRLX AUTOMATION - A COMPLETE SOLUTION Speaker: Timothy Wilson Presented by: Morrell Group

MECHANICAL ROOM 1

10:30 AM - 11:30 AM

THE BEST KEPT SECRET IN INDUSTRIAL MARKETING IS YOU (& YOUR FRIENDS) Speaker: Eddie Saunders, Jr. Presented by: Flex & Friends

1:30 PM - 2:30 PM

ATTRACTING THE NEXT GENERATION WORKFORCE: THE GRAY WAVE IS UPON US. WHAT ARE YOU GOING TO DO? Speaker: Meaghan Ziemba Presented by: Mavens of Manufacturing

9:00 AM - 10:00 AM - TBA

GENERAL MANUFACTURING ROOM 1

10:30 AM - 11:30 AM

9:00 AM - 10:00 AM

THE FUTURE OF ENERGY CONSUMPTION AND ENERGY WASTE REDUCTION Speaker: Mike Dokter Presented by: Consumers Energy

SCALING BATTERY MANUFACTURING WITH A MODERN SMART FACTORY SOLUTION Speaker: Vikram Mankar Presented by: Cybergear Manufacturing Systems

12:00 PM - 1:00 PM

10:30 AM - 11:30 AM

COMBATING INDUSTRY CHALLENGES WITH AUTOMATION Speaker: Michael Buchli Presented by: Dassault Systèmes

DATA MAKES THE DEAL – HOW DIGITIZATION WILL DRIVE THE METAL CUTTING INDUSTRY Speaker: Dr. Götz Marczinski Exhibitor: CIMSOURCE GmbH

1:30 PM - 2:30 PM

RFID, INC. Speaker: James Heurich Presented by: RFID 16

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

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Automation, Priming, Adhesive Dispensing and Soldering Experts

Come visit us at Booth

706!

Are you looking for a team to work with you to bring your production to the next level? Hil-Man and Precision Dispense Technologies are proven experts to help you:

12:00 PM - 1:00 PM

DECOMMODITIZATION AND SUPPORTING THE AMERICAN MANUFACTURING SUPPLY CHAIN TBA Speaker: Anja Redzepagic Presented by: ARCH Cutting Tools

• Improve the quality of your output • Streamline your workflow to optimize your workers’ productivity

1:30 PM - 2:30 PM

THE NEED FOR YOUR COMPANY TO HAVE A DEFINED ASSET RECOVERY PLAN FOR SURPLUS ITEMS Speaker: Dale Watkoski Exhibitor: BTM Industrial

SMART TECHNOLOGY ZONE MICHIGAN MANUFACTURING TECHNOLOGY CENTER (MMTC) As manufacturers work to improve efficiencies, fill talent gaps, increase profitability and stay competitive, a strategic advantage can be found in the application of relevant advanced manufacturing technologies. To ensure manufacturers of all sizes find success in their implementations, experts from the Michigan Manufacturing Technology Center’s (The Center) Industry 4.0 team will provide informative, interactive presentations designed specifically for smaller manufacturers, complete with live demos of relevant technologies in their Smart Technology Zone at the 2022 Advanced Manufacturing Expo.

hil-manautomation.com • precision-dispense.com (616) 741-9099 • 260 E. Roosevelt Ave., Zeeland, MI 49464

Affordable Advanced Manufacturing Training

The Center’s presentations will provide an overview of what steps to take to effectively implement technologies, starting with data collection to gain insight into current performance then growing from there to tackle the biggest opportunities for improvement. Are your conveyor systems not as efficient as they could be? Is your current rack storage system insufficient? PHI is your one stop for all your material handling needs Call or email us! 616-895-6822 info@progressivehandlinginc.com VISIT US AT AME BOOTH 210

Thompson M-TEC in Holland offers customized training at our facility or yours. We provide advanced automation classes including:

mtec.org

616.738.8935

• FANUC Robotic Programming • FANUC Electrical and Mechanical • Hydraulic/Pneumatic Controls • Allen-Bradley/Siemens PLC Look for Robotic Weld Cell training in spring 2023.

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ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

ADVANCED MANUFACTURING

PRODUCT SPOTLIGHT

The One Workforce for West Michigan Manufacturing (1Work) program is creating and strengthening the talent pipelines for Michigan manufacturers.

MAPAL offers efficient and economical solutions for the complete machining process in die & mold. Versatile and precise high performance tools in both standard and special tool-holders with narrow contours and minimal radial run-out. Polishing effort and reworking are reduced thanks to a constant surface finish in the milling process. Visit us at AME booth 1005. MAPAL INC. 4032 Dove Road • Port Huron, MI www.mapal.com

By partnering with local employers and community organizations, 1Work identifies individuals who can use upskilling, or are underemployed, who may benefit from developing new skills to help them succeed in the manufacturing workplace. GRCC and our partners are increasing the skill level of available workers to fill existing job openings in wellpaying, middle- and high-skilled, high-growth jobs. This program provides financial assistance, as well as personal and professional support, for those who are working to improve their family’s quality of life. GRCC Tassell MTEC 622 Godfrey Ave SW • Grand Rapids , MI 49503 grcc.edu/oneworkforce

Over the last decade, Women in Manufacturing (WiM) has grown to be the only national and global trade association dedicated to providing year-round support to women who have chosen a career in the manufacturing industry. WiM encompasses manufacturers of all types and welcomes individuals from every job function — from production to the C-Suite. Membership is available to women and men working within or with the manufacturing sector. The WiM Western Michigan Chapter operates in and around the Grand Rapids region. Chapters provide excellent opportunities for you to expand your local network, build valuable business relationships, and enjoy industryrelated programming. To learn more about WiM and the local chapter check them out on the web/social media (scan the QR codes at left). Women in Manufacturing - Western Michigan Chapter Visit us at AME Booth 1205 18

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

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At Motion, we provide our customers with more brands, more products and more choices. Motion’s customers have instant access to more than 12 million unique MRO/OEM parts through our vast distribution network, sourced from a global manufacturing base. For more information come see us in booth 412 at AME 2022 or visit motion.com.

SCAN HERE TO LEARN MORE

SEVERE CONTAMINATION AND MOISTURE?

YOU’RE COVERED WITH TIMKEN. Increase uptime – even in harsh, dirty applications – with the Timken® Type E mounted tapered roller bearing Secondary Sealing System.

Scan the QR code to learn more about Hurco Automation!

UNRIVALED MULTI-POINT SEALING SYSTEM

Upgraded triple-barrier internal bearing seal • Two contact lips and one rigid middle labyrinth section to help retain grease and reduce contamination ingress • New enhanced seal material to provide greater performance with 2X more abrasion resistance than the industry standard nitrile seal Points of Sealing:

Locking collar

Grease in cavity of end cover

Triple-lip external rubber through shaft seal

External secondary cover

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7/19/2022 9:48:32 AM ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022 19

EXHIBITORS

ADVANCED MANUFACTURING EXPO: AUGUST 11-12, 2022

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AUTOMATION HALL

2022 Advanced Manufacturing Expo Magazine & Program

Articles inside

CASE STUDIES ROUND UP: SAVING MANUFACTURERS TIME AND MONEY

BEARING DOWN: HOW THE INTERNET OF THINGS IS REDUCING FACTORY DOWNTIME

EXHIBITOR PRODUCT SPOTLIGHT

ESCAPING DATA ISLAND

MOVE OVER: AMRs COMING TO A FACTORY NEAR YOU

DATA DONE RIGHT: TMS OFFERS MANUFACTURERS REDUCED INVENTORY, COSTS