IndustrialMachineryDigest.com | January 2024
North America’s Manufacturing Resource for Industry Professionals Since 1986
Talking Shop with: Logan Skelly — Sales Manager at Flex Machine Tools Revolutionizing Industry: A Deep Dive into Flex Machine Tools' Innovative Product Range and Impact on Manufacturing What is the State of the U.S. Economy? Toolbox Talks: The Secret Weapon In Enhancing Maintenance Safety and Compliance Global Shop Solutions Introducing TwinBox: RoboDK’s Compact Solution for Production Robot Integration SME Launches Training and Electric Vehicle Certification to Address High and Unmet Demand for Electrification Skills Four Predictions for 2024: AI Set to Supercharge Robotic Automation
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Table of Contents
January 2024 8 10 14
EDITORIAL DIRECTION INDUSTRY NEWS BUSINESS 4.0 What is the State of the U.S. Economy? By: Michele Nash-Hoff
18
TALKING SHOP
22
SAFETY & MAINTENANCE
Logan Skelly — Sales Manager at Flex Machine Tools Toolbox Talks: The Secret Weapon In Enhancing Maintenance Safety And Compliance By: Sanjay Murthi
26
18
MANUFACTURING SHOWCASE Global Shop Solutions Get ERP Software Right the First Time
32
AUTOMATION & ROBOTICS
36
WORKFORCE DEVELOPMENT
Introducing TwinBox: RoboDK’s Compact Solution for Production Robot Integration SME Launches Training and Electric Vehicle Certification to Address High and Unmet Demand for Electrification Skills Designed for Positions Working with Electric Vehicles and E-Mobility
38
NEW TECHNOLOGY
40
PROCESS
Siemens Revolutionizes Engineering Simulation with HEEDS AI Simulation Predictor and Simcenter Reduced Order Modeling Four Predictions for 2024: AI Set to Supercharge Robotic Automation
32 36
By Anders Billesø Beck
42
INDUSTRY INSIGHT
44 48 49 50
PRODUCT SHOWCASE
Red Bull Ford Powertrains Pursues the Sustainable Future of Motorsport with Siemens Xcelerator
SURPLUS BUYING & SELLING CLASSIFIEDS ADVERTISER INDEX
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Editorial Direction Happy New Year and welcome to the January issue of Industrial Machinery Digest (IMD). As we usher in the new year, we're thrilled to present articles capturing the pulse of the ever-evolving industrial machinery and technology landscape. In "Business 4.0," Michele Nash-Hoff provides a comprehensive analysis of the U.S. economy, offering valuable insights for navigating the complexities and opportunities in the year ahead. Our "Talking Shop" feature takes us into the world of Flex Machine Tools, where Logan Skelly, Sales Manager, offers a deep dive into the innovative product range and the impact it has on revolutionizing the industry. It's a fascinating exploration into the cutting-edge solutions that are shaping the future of manufacturing. "Safety & Maintenance" with Sanjay Murthi unveils the power of "Toolbox Talks" for enhancing safety and compliance in maintenance practices. The "Manufacturing Showcase" highlights Global Shop Solutions, where Dusty Alexander, Director of Marketing and President & CEO, shares insights on getting ERP software right the first time. In a world where efficiency is key, understanding the importance of ERP software is crucial for successful manufacturing operations. Our "Automation and Robotics" feature introduces TwinBox, RoboDK’s compact solution for production robot integration, shaping the future of automation. "SME Launches Training and Electric Vehicle Certification" in our "Workforce Development" segment addresses the high demand for electrification skills, positioning SME at the forefront of essential training. In "New Technology," Siemens revolutionizes engineering simulation with HEEDS AI Simulation Predictor and Simcenter Reduced Order Modeling, changing the game in engineering. Anders Billesø Beck, VP of Innovation and Strategy at Universal Robots, predicts "Four Predictions for 2024: AI Set to Supercharge Robotic Automation" in our "Process" section. Finally, in "Industry Insight," Red Bull Ford Powertrains pursues the sustainable future of motorsport with Siemens Xcelerator. Explore how technology and sustainability converge in the dynamic world of motorsport. As we embark on a new year filled with possibilities, we hope the articles in this issue inspire and inform you. Thank you for being a part of the IMD community. If you have any feedback or suggestions, feel free to reach out.Wishing you a prosperous and innovative year ahead!
William Strickland
William Strickland Publisher, IMD
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Industry News
INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industry's top companies. WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com
AEM Hall of Fame Honors Akio Takeuchi and Susanne Cobey At the Association of Equipment Manufacturers (AEM) Annual Conference in Ft. Lauderdale, Florida, the induction of Akio Takeuchi and Susanne Cobey into the AEM Hall of Fame marked a celebration of Akio Takeuchi visionary leadership in the equipment manufacturing industry. Akio Takeuchi, the founder of Takeuchi Manufacturing, has spent six decades pioneering innovations. His creation of the world's first compact excavator and subsequent developments like the offset boom excavator and compact track loader have Susanne Cobey left an enduring legacy. Takeuchi's commitment to listening to customer needs and fostering teamwork has been pivotal. Susanne Cobey, CEO of Eagle Crusher, joined the company in 1970 and ascended to leadership in 1990. Facing challenges in the crusher industry during the 1980s, Cobey ingeniously propelled Eagle Crusher into the commercial recycling sector, notably with the Jumbo 1400 plant in 1984. This move revolutionized the American recycling landscape, saving substantial concrete and asphalt from landfills. Cobey's leadership, particularly as a female pioneer, extends beyond industry success; she actively promotes and supports women in the industry, serving as an inspiration. The AEM Hall of Fame, recognizing industry luminaries since 1993, now includes Akio Takeuchi and Susanne Cobey, bringing the total number of inductees to 69.
www.IndustrialMachineryDigest.com 10 | IMD January 2024
CERATIZIT Appoints Dave Conger as National Sales Manager for West Region CERATIZIT, a leading cutting tool industry player, is pleased to announce the appointment of Dave Conger as the National Sales Manager for the West Region. With an impressive 26-year Dave Conger background in cutting tool industry sales leadership and hands-on machining expertise, Conger, based in Texas, brings valuable experience to the role. Conger, a Stephen F. Austin State University business administration graduate, emphasizes the significance of listening to customer needs and responding with passion and professionalism for success. His management training, coupled with an elite development program, equips him to focus on leadership that drives sales growth and enhances brand awareness. Throughout his award-winning career, Conger has led sales teams at both national and regional levels, emphasizing personnel development and fostering strong channel partnerships. His customer-centric approach aims to integrate diverse skill sets into cohesive teams, building robust internal and external relationships. CERATIZIT USA, Inc., part of the CERATIZIT Group, specializes in designing and manufacturing high-quality standard and custom tooling for the metalworking industry. Headquartered in Schaumburg, Illinois, the company serves various industry segments, including automotive, aerospace, and energy. CERATIZIT USA, with its specialized staff, expansive product portfolio, and ITAR registration, provides manufacturers with comprehensive application engineering, service, and training support for maximum productivity and cost-effectiveness.
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CERATIZIT Executive Board Restructures Responsibilities Post-Thierry Wolter's Retirement CERATIZIT, a global carbide manufacturing leader, has undergone a reshuffle in its Executive Board responsibilities effective December 1, 2023, following the retirement of long-serving Executive Board Member, Thierry Wolter. The restructured Executive Board now comprises Melissa Albeck, Andreas Lackner, and Frank Thomé. Thierry Wolter, who played a pivotal role in CERATIZIT's growth over three decades, especially in the cutting tool sector, decided to retire, passing on the entrepreneurial legacy to the next generation. CERATIZIT has evolved into one of the world's largest carbide manufacturers under Wolter's leadership. The reorganization includes Andreas Lackner, serving as the Executive Board Spokesman, overseeing production across all CERATIZIT divisions and managing the strategic aspect of sustainability for the entire Plansee Group, as he holds a position on the Plansee Group's Executive Board. Melissa Albeck takes on the responsibility for cutting tool sales, succeeding Thierry Wolter, and oversees CERATIZIT's American business. Completing the trio, Frank Thomé manages sales for the Hard Material Solutions and Global Tungsten & Powders divisions, along with overseeing the company's Asian business, including the CB-CERATIZIT joint venture. With this restructuring, Albeck and Thomé are positioned to play key roles in driving the company's growth strategy. The focus for future expansion is set on Asia and the American continent to surpass market growth and secure the company's position as a top-three player in the carbide industry.
EMUGE-FRANKEN Earns ANCA 2023 Tool of the Year Award for Revolutionary End Mill EMUGE-FRANKEN USA, a prominent manufacturer of rotary tools, proudly announces its win of the ANCA 2023 Tool of the Year Award for the groundbreaking FRANKEN Cera-Cut End Mills design. Presented at the EMO event in September, the award recognizes EMUGE-FRANKEN's innovative, precise, and versatile tool, combining carbide and ceramic materials. ANCA, a leading CNC grinding machine manufacturer, annually hosts the competition, inviting global cutting tool manufacturers to showcase their expertise in design and production using ANCA technology. Bob Hellinger, President of EMUGE-FRANKEN USA, expressed his honor at receiving the esteemed ANCA Tool of the Year Award, emphasizing the company's
commitment to precision, innovation, and quality. The FRANKEN end mill secured victory based on engineering excellence, notably its close adherence to specified nominal tolerance in diameter and profile, outperforming competing tool submissions. Additionally, the FRANKEN end mill excelled in profile and 3D edge radius measurements, solidifying its status as a revolutionary tool.
SpiTrex Orthopedics Chooses Flexxbotics for Robot-Driven Manufacturing Enhancement Flexxbotics, a leader in workcell digitalization for robotdriven manufacturing, announces its collaboration with SpiTrex Orthopedics (SpiTrex), a global leader in medical device contract manufacturing. SpiTrex has opted for Flexxbotics' solution to optimize its FOBA laser marking machine workcells, ensuring robot-driven manufacturing with autonomous process control. The Flexxbotics solution empowers robots to communicate directly with the FOBA laser marking system, facilitating real-time job changes within sequence and reducing changeover time to a mere 10 minutes, twice a week. The robots also integrate seamlessly with the vision system to autonomously sort parts based on laser marking results, ensuring a closed-loop quality process for enhanced yields. Brett Gopal, Senior Vice President of Operations at SpiTrex Orthopedics, praises Flexxbotics' precision, cycle-time efficiency, and unique autonomous process control. The solution allows robots to use COGNEX camera images for in-line inspection, determining part pass/fail status and alerting other workcells to quality issues. This closed feedback loop contributes to higher tolerance parts and a 20% reduction in overall lead time, subsequently boosting throughput and profitability. SpiTrex's selection criteria for Flexxbotics included the ability to autonomously configure robots and laser markers for each job, closed-loop in-line inspection, open connectivity with existing systems, quick changeover capabilities, and scalability for factory-wide implementation. Tyler Bouchard, Co-founder & CEO of Flexxbotics, expresses pride in collaborating with SpiTrex and emphasizes the importance of autonomous process control for smart factories. Flexxbotics' FlexxCORE™ technology enables seamless robot-machine coordination, supporting advanced machining operations in sectors like medical, defense, aerospace, and automotive.
Fronius Achieves Gold Rating in EcoVadis Sustainability Assessment Fronius, an Upper Austrian family company, has secured a gold medal in the latest sustainability rating by EcoVadis, a globally recognized agency specializing in sustainability assessments. EcoVadis evaluates over 100,000 companies across 175 countries and 200 industries annually, focusing on key areas such as environment, labor and human rights, ethics, and sustainable procurement. INDUSTRIAL MACHINERY DIGEST.COM
IMD | 11
Fronius, known for its commitment to sustainability, has consistently improved its performance and achieved a gold medal for the first time, placing it among the top 5% most sustainable companies in its industry. The company's dedication to sustainability is reflected in various initiatives, including the recent completion of the phasing out of gas usage at all its production sites in Austria. This significant step aligns with Fronius' future-oriented sustainability strategy and contributes to substantial energy savings and a notable reduction in carbon emissions. Katrin Helmberger, Head of Corporate Sustainability at Fronius, expressed pride in the recognition from EcoVadis, emphasizing the company's commitment to continuous improvement in sustainability practices. The gold rating not only marks a significant achievement but also serves as inspiration for Fronius to further enhance its sustainability efforts. In addition to the gas phase-out initiative, Fronius has invested in photovoltaic systems on its production site roofs, delivering an independent output of 4 MWp. The company also ensures that its purchased electricity is 100% certified green electricity, showcasing a holistic approach to sustainable operations.
Robots to Address Japan's 2024 Labor Shortage Dilemma Japan anticipates a labor shortage crisis in 2024 due to new overtime regulations affecting truck drivers, termed the '2024 problem.' With a commitment to improving working conditions, the government's overtime cap necessitates innovative solutions to mitigate disruptions. Japan, a global leader in robot manufacturing, is strategically leveraging automation to address logistical challenges and other industry issues arising from the impending labor law changes. The average annual working hours for heavy truck drivers in Japan exceed the national average by 444 hours, posing a significant challenge. To optimize efficiency and adhere to the new regulations, the integration of robotic solutions is underway. Mobile robots designed for transportation and logistics are streamlining tasks such as loading and unloading cargo, saving truck drivers up to 25% of their working time during shifts. Warehouse robots, ranging from compact autonomous mobile robots to large-scale automated
12 | IMD January 2024
storage and retrieval systems, are also playing a crucial role. They enhance the speed and safety of goods movement, reducing reliance on human workers for heavy loads and handling dangerous materials. Professional service robots, especially those dedicated to transportation and logistics, have seen remarkable growth globally. In 2022, sales of such robots increased by 44%, with over 86,000 units sold. The adoption of automation technology is deemed essential in various sectors of the Japanese economy, driven by regulatory changes and demographic shifts. Takayuki Ito, Vice President of the International Federation of Robotics, emphasizes that robotics and automation offer effective solutions for the challenges posed by the trucking industry and other sectors. The application of automation technology is expected to become integral to shaping the future workplace landscape in Japan. The International Robot Exhibition (iREX) in Tokyo, scheduled for November 29 to December 02, will provide a platform to showcase the latest advancements and innovations in the field of robotics.
Long-time Jergens Inc. Representative, Tom Reid, Retires After 25 Years of Dedicated Service in Canada Jergens Inc. bids farewell to Tom Reid, its esteemed representative dedicated to Canadian territories, as he embarks on his well-deserved retirement. Having been an integral part of Jergens since 1998, Mr. Reid contributed significantly to the sales and Tom Reid service of products across all three Jergens business units— Workholding, Lifting, and Fasteners. Expressing gratitude for his fruitful association with Jergens, Reid reflects on the positive relationship built over the years. Jergens reciprocates the appreciation, acknowledging his skills, support, and accomplishments during his quarter-century tenure. Matt Schron, Jergens' Vice President and General Manager, extends the organization's thanks to Reid, wishing him and his family the very best in retirement. With a manufacturing career spanning over four decades, Tom Reid commenced his journey in 1979, following in his father's footsteps. Over the years, he served in various capacities, including as a manufacturers' agent, distributor, and Jergens Canadian Sales Manager. Since 1998, he played a pivotal role in representing Jergens, eventually focusing solely on the company in 2007. As Reid steps into retirement, Barry Schwartz assumes the role of Jergens Business Development Manager for the Canadian markets, with Reid providing valuable support
during the transition. Tom Reid, a father of three grown children, resides in Orangeville, Ontario, with his wife Ali and their dog, Koko. Jergens Inc., a global CNC machining workholding products leader, expresses gratitude for Tom Reid's dedication and commitment, emphasizing its ongoing commitment to assisting customers in achieving leaner and more profitable manufacturing.
KUKA Unveils Next-Gen Mobile Robotics at MODEX 2024 KUKA Robotics is set to showcase cutting-edge mobile robots at MODEX 2024 in Atlanta (Booth B4003). The spotlight includes the KUKA KMP 1500P autonomous mobile platform, transforming intralogistic automation, and the KUKA KMP 600-S diffDrive mobile platform AGV, setting new safety standards with laser scanners and 3D object detection. KUKA KMP 1500P Autonomous Mobile Robot (AMR) The KMP 1500P redefines intralogistic processes in production and storage. With a 60 mm stroke and precision positioning, it efficiently transports up to 1.5 tons of materials, handles goods, and optimizes warehouse processes. The AMR's flexibility, differential drive, and autonomous adaptability make it adept at navigating dynamic and complex environments. Safety features
include 3D cameras, laser scanners, and IP class 54 protection. The 24/7 intelligent charging management enhances operational efficiency. KUKA KMP 600-S diffDrive Mobile Platform AGV Designed for demanding loads, the KMP 600-S diffDrive AGV achieves speeds up to 2 meters per second in all directions, offering a payload capacity of 600 kg. Its integrated lifting device swiftly handles loads, lifting up to 60 mm in under 3 seconds. Operating without safety fencing ensures maximum freedom of movement for employees. Front and rear-mounted laser scanners, coupled with 3D object detection, enhance safety and seamless integration into existing production environments. The IP 54 design ensures reliability in challenging industrial conditions. Both platforms come with applications programmed in Java, simplified commissioning through a manual controller, and efficient maintenance with tool-free access to components. The innovative fleet manager, KMReS, streamlines integration, ensuring an ideal balance of cost efficiency and safety.
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IMD | 13
Business 4.0
What is the State of the U.S. Economy? By: Michele Nash-Hoff
T
here are many different opinions on the state of the U.S. economy. This is normal when we are entering an election year. The political party in power wants the economy to appear good or better than the previous administration, and the opposing political party wants it to appear worse than when they were in power. Let’s examine what are the key economic indicators as well as other data to determine the true state of the U.S. economy. According to the website, USA Facts, the key economic indicators are: GDP, inflation, Federal Reserve interest rates, workers’ average hourly wages, unemployment rate, ratio of unemployed people related to job openings, labor force participation rate, trade deficit (imports vs. exports), and Federal debt. USA Facts only reports the figures at the end of the year so the data shown is for 2022 since 2023 hasn’t ended yet.
14 | IMD January 2024
Labor Force Participation Rate The rate is calculated as the labor force divided by the total working-age population. The working age population refers to people aged 15 to 64. This indicator is broken down by age group and it is measured as a percentage of each age group. The labor force participation rate was 66.0% in 2008, and gradually dropped down to 63.3% by January 2020. As a result of the COVID-19 pandemic, it dropped to a low of 61.5% in November 2020 before gradually rising to 62.8% in November 2023.
Ratio of Unemployed People to Job Openings According to the Bureau of Labor Standards, “The ratio of unemployed people to job openings ranged from 0.8 to 1.0 during 2018 and 2019. Over the past 5 years, the number of unemployed people per job opening reached a high of 4.9 in
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Graph: Gross Domestic Product 1970 - 2023
April 2020, when there were 23.1 million unemployed people and 4.7 million job openings. Since October 2021, the ratio has been 0.5 or 0.6 every month…When ratios equal 1.0, there is approximately 1 unemployed person per job opening. When less than 1.0, the labor market is tight, as job openings outnumber the unemployed. When greater than 1.0, there are more unemployed people than available jobs..” The unemployment rate of the United States, which has been steadily decreasing since the 2008 financial crisis, but spiked to 8.1 percent in 2020 due to the COVID-19 pandemic. The annual unemployment rate of the U.S. since 1990 can be found here.
National average wage indexing series, 2001-2022 It looks like wages have nearly doubled in 21 years, but the value of the dollar has changed over time. According to the CPI Inflation Calculator, the ”U.S. dollar has lost 42% its value since 2001; $100 in 2001 is equivalent in purchasing power to about $173.73 today…The dollar had an average inflation rate of 2.54% per year between 2001 and today, producing a cumulative price increase of 73.73%.” Thus we need to deduct 42% from the 2022 wage to compare it to 2001 ($63,795.13 - $27,431.91 = $42,363.23). Thus, the wages only went up by 34% while inflation increased 73.73%.
Federal Fund Interest Rates
Graph: Federal Fund Interest Rates
The Federal Reserve raised interest rates seven times in 2022 and four times in 2023, increasing the target rate from nearly zero (0.25%) in 2020-2021 to 5.25%-5.50% currently. The Fed is expected to hold rates steady when they meet this month. The Fed rate affects the consumer interest rates for mortgages and installment loans for things like cards, home furnishings, and other consumer goods. Mortgage rates have risen from 2.75-3.25 in 2021 to 6.0%-7.9% in 2023. This has stagnated sales for homes and automobiles.
https://www.macrotrends.net/2015/fed-funds-rate-historical-chart
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IMD | 15
Trade Deficit The last year that the U.S. had a positive trade balance by exporting more than we imported was 1979. The trade deficit grew gradually from 1980 – 1999, but accelerated after China was granted Most Favored Nation status in the year 2000. In 2022, the trade deficit of $948.1 billion is a 3.9% increase from 2021.
U.S. Private Sector Job Quality Index The November Job Quality Index report by The Coalition for a Prosperous America states, “The Job Quality Index measures job quality for U.S. production and nonsupervisory workers by comparing workers’ weekly wages to the mean weekly wage for all non-supervisory workers. Those jobs above the mean are classified as high-quality and those below the mean are low-quality… Over the past three decades, the JQI declined because the U.S. economy created more low-quality jobs than it has high-quality jobs. As shown in the Job Quality Index graph, the JQI is down 12.8% from 1990 illustrating the disproportionate growth in low-wage, low-hour jobs.” For my industry of manufacturing, there are two other measures that can be examined to determine the true state of the economy. They are:
Table: National average wage indexing, 2001-2022 Data source: https://www.ssa.gov/oact/cola/AWI.html
Year
Annual Wage
Year
Annual Wage
2001
$32,921.92
2012
$44,321.67
2002
$33,252.09
2013
$44,888.16
2003
$34,064.95
2014
$46,481.52
2004
$35,648.55
2015
$48,098.63
2005
$36,952.94
2016
$48,642.15
2006
$38,651.41
2017
$50,321.89
2007
$40,405.48
2018
$52,145.80
2008
$41,334.97
2019
$54,099.99
2009
$40,711.61
2020
$55,628.60
2010
$41,673.83
2021
$60,575.07
2011
$42,979.61
2022
$63,795.13
Annual Goods and Services Trade Deficit 2000-2022 bea.gov/news/blog/2023-03-08/2022-trade-gap-9453-billion
US ISM Manufacturing PMI The Institute of Supply Management Purchasing Managers
Graph: Job Quality Index
Index “is a diffusion index summarizing economic activity in the manufacturing sector in the US. The index is based on a survey of manufacturing supply executives conducted by ISM. Participants are asked to gauge activity in a number of categories like new orders, inventories, and production and these sub-indices are then combined to create the PMI… A PMI above 50 would designate an overall expansion of the manufacturing economy whereas a PMI below 50 signifies a shrinking of the manufacturing economy.
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US ISM Manufacturing PMI was at a level of 46.70 on November 30, 2023, unchanged from 46.70 for October and down from a recent high of 64.70 in March, 2021. The PMI dropped to 49.00 for the November, 2022 report, so we have been in a shrinking economy for 13 months.
U.S. Manufacturing Technology Orders According to the November report published by AMT, The Association For Manufacturing Technology, “orders for manufacturing technology…continued to fall relative to 2022. Through October 2023 orders totaled $4.05 billion, 13.5% behind the total for the first 10 months of 2022.
Conclusion Adding to the above data is the fact that vehicle gas prices have escalated since 2020. According to Finder, “Gas prices in over the last 12 months are well above the national average over the last six years, hitting $4.99 a gallon in the week of June 16, 2022 — a week in which Californians paid a whopping $6.43 per gallon…The national average gas price this week [December 7th] is $3.22, down from $3.27. US gas prices over the last year are among the highest since 2018. California has the highest gas prices in the nation, followed by Hawaii as a close second, and Washington, Nevada, and Oregon
making up the top five. Texas has the lowest gas price ($2.68) in the nation followed closely by Mississippi ($2.72) and Oklahoma ($2.74). According to the U.S. Government Accountability Office, “Last year, U.S. consumers saw the largest annual increase in food prices since the 1980s. While food prices generally increased about 2% in prior years, they increased about 11% from 2021 to 2022…Food prices also varied by locality. For example, the highest increase between 2021 and 2022 was seen in Detroit Michigan (about 14.5%). The lowest (about 5%) occurred in the Miami-Fort Lauderdale, Florida metro area…Finally, food price increases from 2021 to 2022 varied by food group. For example, prices for grains and bakery products increased by about 13%, while fruits and vegetables increased by about 9%. Similarly, dairy products increased by about 12%, but meats, poultry and fish increased about 10%.” I am not an economist qualified to do an educated analysis of all of the above data, but it is obvious to me that the U.S. economy has some serious problems that need to be urgently addressed if we want to avoid a prolonged recession. The question that voters ask themselves in an election year, “Am I better off now than I was under the previous administration.” The answer to that question will determine the outcome of the next election.
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IMD | 17
Talking Shop
We're focusing on ergonomic solutions, such as our custom-designed products that alleviate operational pain points. FEATURING:
TALKING SHOP WITH: Logan Skelly — Sales Manager at Flex Machine Tools
Revolutionizing Industry: A Deep Dive into Flex Machine Tools' Innovative Product Range and Impact on Manufacturing In this edition of Talking Shop, we're joined by Logan Skelly, the Sales Manager at Flex Machine Tools. Based in Wapakoneta, Ohio, Flex Machine Tools is a trailblazer in the industrial machinery sector. The company is renowned for its innovative and efficient products, including the FlexCNC long bed vertical machining center, FlexJet waterjet cutting solution, FlexArm tapping and die grinding arms, FlexBEAM CNC, and FlexErgo line. These products highlight the company's commitment to precision, efficiency, and ergonomic solutions, addressing various industrial needs and enhancing productivity.
IMD: We're thrilled to be here with Flex Machine Tools. Logan, could you tell us more about your latest innovations this year? Skelly: Absolutely! We're excited to showcase our latest innovations, including the limited edition A32 FlexArm tapping arm. We've given it a unique camo design and are donating 10% of all proceeds from this edition to the
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Wounded Warriors Project. IMD: That sounds fantastic. What other products are you highlighting? Skelly: We're focusing on ergonomic solutions, such as our custom-designed products that alleviate operational pain points. For instance, we've adapted MAG drills to be more
IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
The FlexCNC spacious open bed facilitates uninterrupted workflow with quick and easy refixturing during machining cycles.
user-friendly by mounting them on a FlexArm, significantly easing their use and improving accuracy. IMD: That’s quite innovative. Any other ergonomic solutions you’re excited about? Skelly: Definitely. We've transformed heavy grinders into more manageable tools. By adding a balance arm, operators can use larger discs without fatigue, enhancing efficiency significantly. IMD: Material handling is a big challenge in the industry. How is Flex Machine Tools addressing this? Skelly: We've developed a part manipulator arm capable of lifting 250 pounds, mounted on a mobile base for versatility. It's particularly useful in our own shop for tasks like changing lathe chucks or loading heavy parts onto machine platters. IMD: The FlexArm tapping arm is a legacy product. Can you elaborate on its benefits? Skelly: The FlexArm tapping arm revolutionizes the tapping process, offering perfect holes every time with minimal effort. It's especially useful for avoiding tap breakages, with features like automatic depth stop and manual mode for precision. IMD: And the FlexCNC? Skelly: Our FlexCNC is a game-changer for handling long, large parts. Its open bed design and pendulum mode increase throughput and accuracy, making it a valuable asset in the fabrication industry. IMD: Tell us more about the FlexJet water jet.
Skelly: The FlexJet is our latest high-performance water jet. It features high rapids, advanced motion control software, and is available in three models. We're excited about its potential impact on the water jet sector.
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IMD | 19
Deep Dive into Flex Machine Tools' Innovative Product Range FlexCNC Long Bed Vertical Machining Center The FlexCNC stands out for its ability to handle long, large parts, a common challenge in the fabrication industry. Its unique open bed design and pendulum mode enhance productivity by allowing simultaneous setup and machining operations, leading to higher throughput and accuracy. This machine is a testament to Flex Machine Tools’ commitment to solving complex machining challenges.
FlexJet Waterjet Cutting Solution
The FlexArm Mag Drill arm reduces operator fatigue by counterbalancing the weight of heavy mag drills.
Entering the water jet sector with a splash, the FlexJet is a high-performance cutting tool characterized by its high rapids and advanced motion control software. Available in three models, it caters to various cutting needs, ensuring precision and efficiency. Its introduction is a significant move for Flex Machine Tools, showcasing their expansion into diverse machining technologies.
FlexArm Tapping and Die Grinding Arms The FlexArm series, including the innovative tapping arm, revolutionizes processes like tapping, grinding, and drilling. These arms provide ergonomic solutions, reducing operator fatigue and increasing precision. The tapping arm, particularly, is renowned for its ability to produce perfect tapped holes while minimizing tap breakage, a common issue in manual tapping.
FlexCNC excels at machining long parts with its extended travel from 10 feet up to 50 feet.
FlexBeam CNC for Structural Machining The FlexBeam is another example of Flex Machine Tools' engineering excellence. Designed for structural machining, this CNC machine provides precision and efficiency in processes like drilling, milling, and tapping on large structural components.
FlexErgo Ergonomic Solutions Flex Machine Tools’ commitment to
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FlexArm tapping arms deliver reliable and efficient tapping across diverse metals and sizes (00 - 2”)
ergonomic designs is evident in the FlexErgo line. These products, such as the part manipulator arm, are designed to ease the physical strain on operators, improving safety and efficiency in the workplace. Their solutions in handling heavy tools and components demonstrate their understanding of the practical challenges in industrial environments.
Customer Testimonials and Industry Applications Customer Experiences Flex Machine Tools has garnered praise from various sectors for their products' impact on efficiency and ergonomics. Customers from the automotive, aerospace, and manufacturing industries have noted significant improvements in their operations, highlighting the ease of use and precision of Flex Machine Tools' equipment. These testimonials underscore the real-world benefits of their machinery, from reduced operator fatigue to increased productivity.
Impact on Industry Flex Machine Tools has been instrumental in transforming traditional manufacturing processes. Their machinery has enabled companies to tackle complex tasks with greater accuracy and less physical strain. Particularly in industries
where precision and efficiency are paramount, such as aerospace and automotive manufacturing, Flex Machine Tools' innovations have been game-changers.
Future Prospects Looking ahead, Flex Machine Tools continues to innovate, focusing on integrating advanced technologies like AI and automation into their products. Their commitment to ergonomic design and operational efficiency ensures they remain at the forefront of the industrial machinery industry. Flex Machine Tools stands as a testament to the power of innovation, precision, and ergonomic design in enhancing industrial operations. Their diverse product range, backed by positive customer feedback and significant industry impact, positions them as a leader in the field.
Flex Machine Tools In an era where efficiency, precision, and worker safety are paramount, Flex Machine Tools emerges as a beacon of innovation and reliability. Their commitment to solving complex industrial challenges through advanced technology and thoughtful design not only sets them apart but also drives the industry forward. As they continue to evolve and expand their product offerings, Flex Machine Tools remains a key player in shaping the future of industrial machinery.
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IMD | 21
Safety & Maintenance
Image by Drazen Zigic on Freepik
Toolbox Talks: The Secret Weapon In Enhancing Maintenance Safety And Compliance By: Sanjay Murthi
T
oolbox talks are an integral part of the manufacturing maintenance sector, serving as short, informal meetings focused on workplace safety and operational issues. These discussions provide crucial insights and guidance, tailored specifically to address the unique challenges and hazards encountered in a manufacturing environment. Since they aid in fostering a culture of safety awareness, toolbox talks play a pivotal role in preventing accidents and ensuring a secure (and compliant) workplace. This article delves into how these talks specifically tackle the multifaceted challenges of safety and compliance in the manufacturing maintenance realm. The goal is to help
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understand how toolbox talks not only raise awareness but also actively contribute to mitigating risks and adhering to stringent regulatory standards, thereby promoting a safer and more compliant workplace.
Toolbox Talks in Maintenance Safety In manufacturing maintenance, workers are frequently exposed to a range of hazards. Electrical risks — including electrocution, short circuits, and sparks leading to fires — involve exposure to live wires or faulty electrical equipment, posing significant dangers. Machinery malfunctions can lead to catastrophic accidents, especially with heavy or high-speed equipment.
IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
These include breakdowns, unexpected start-ups, or equipment failures causing injuries. Ergonomic injuries, often overlooked, arise from repetitive tasks or improper handling of equipment, lifting heavy items, or poor workstation design, and are known for leading to long-term musculoskeletal issues. Some other, frequently occurring risks include: » Chemical exposures: contact with hazardous substances causing health risks. » Falls and slips: due to wet floors, uneven surfaces, or working from heights. » Noise exposure: this leads to hearing loss from prolonged exposure to loud machinery. Toolbox talks are instrumental in cultivating a robust safety culture, emphasizing preventive measures and proactive safety management. They enable teams to identify potential hazards and discuss practical solutions, such as proper use of safety gear or machinery operation protocols. For instance, a toolbox talk could focus on the correct way to handle a new high-speed cutting machine, addressing both operational procedures and safety precautions, thereby reducing the risk of accidents and reinforcing a culture of safety vigilance.
Compliance Challenges in Manufacturing Maintenance Compliance in manufacturing maintenance is a complex landscape, dominated by stringent standards like those set by OSHA and various local safety regulations. These standards cover a broad spectrum of issues, from equipment safety to employee training requirements. For example, OSHA's guidelines on hazardous energy control (lockout/tagout procedures) are crucial for maintenance personnel to understand and implement to avoid severe accidents. But, as stated earlier, the regulatory landscape includes an array of considerations: » OSHA standards: meeting guidelines on hazardous energy control, machine guarding, and PPE usage. » Local safety regulations: adhering to specific local or state safety and environmental standards. » Environmental regulations: compliance with waste disposal and air quality standards. » Fire safety regulations: ensuring adherence to fire safety protocols and equipment maintenance. » Emergency response preparedness: preparing for accidents, natural disasters, or other emergencies. » Training and certification requirements: ensuring all workers are appropriately trained and certified. Toolbox talks are an effective platform to keep staff updated on evolving compliance standards and best practices in maintenance safety. Regularly including topics on recent regulatory updates or introducing new safety procedures ensures that all team members are informed and prepared.
One such talk could focus on new amendments to machine guarding regulations, explaining the changes and how they impact daily maintenance activities, ensuring that the team not only complies with the law but also adopts best safety practices. Another iteration of a toolbox talk could focus on the latest updates in hazardous chemical handling and storage regulations. This session could detail how new labeling requirements and safety data sheet formats must be integrated into the maintenance team's routines. Discussing these changes helps ensure that team members are aware of the proper procedures for handling, storing, and disposing of chemicals, thereby not only complying with the updated regulations but also significantly enhancing workplace safety and reducing the risk of chemical-related incidents.
Implementing Effective Toolbox Talks Effective toolbox talks are tailored to address specific safety and compliance needs unique to each maintenance team. This involves customizing content to reflect the particular machinery, machinery maintenance, other processes, and risks inherent in the team's daily operations. A team working with advanced robotic assembly lines would benefit from talks that focus on the safe interaction with automation and emergency protocols specific to such equipment. That’s why you must ensure topics are directly relevant to the team's daily tasks and potential risks, and regularly update content to reflect changes in equipment, procedures, or regulations. Use interactive methods like Q&A sessions, hands-on demonstrations, or group discussions to maintain engagement — incorporating real-life incident analyses can make sessions more relatable. One of the many must-haves with toolbox talks is consistency — hold talks regularly, but avoid over-scheduling to maintain their effectiveness and perceived value. Also, try to actively seek feedback from attendees and use it to improve future sessions. This could involve modifying the format, content, or delivery based on employee suggestions. To engage maintenance personnel effectively, toolbox talks should incorporate interactive elements like hands-on demonstrations or analysis of real-world incident case studies. This approach keeps the sessions engaging and provides practical, tangible learning experiences. One example — a hands-on demonstration of the correct procedure to shut down a malfunctioning conveyor belt effectively reinforces the learning and ensures better retention and application of safety protocols.
Measuring Toolbox Talk Effectiveness in Maintenance Key Performance Indicators (KPIs) are essential to measure the impact of toolbox talks on safety in maintenance operations. These metrics provide quantitative data to INDUSTRIAL MACHINERY DIGEST.COM
IMD | 23
Image by Drazen Zigic on Freepik
assess whether these talks are effectively reducing accidents and improving adherence to safety protocols. These KPIs include: » Incident rates: frequency and severity of workplace accidents and injuries. » Near-miss reports: tracking incidents that could have led to accidents but were narrowly avoided. » Compliance audit results: regular checks on adherence to safety and regulatory standards. » Employee safety training completion: rate of employees completing mandatory safety training. » Employee feedback and engagement: surveys and feedback mechanisms gauging employee participation and understanding. » Toolbox talk attendance records: monitoring how many workers are actively participating in these talks. A noticeable decrease in incident rates post-implementation would indicate a positive impact on workplace safety. Obtaining and utilizing feedback from maintenance staff is crucial for the continuous improvement of toolbox talks. Methods like post-talk surveys, interactive feedback sessions, and observational feedback provide direct insight into the effectiveness of the talks. Regular review meetings to discuss feedback results and observations can lead to adjustments in the talks, ensuring they remain relevant, engaging, and effective in addressing the evolving needs of the maintenance team.
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The Final Piece in Your Safety and Compliance Puzzle Toolbox talks are indispensable in enhancing safety and compliance in the manufacturing maintenance sector. Their role in fostering a culture of safety awareness, educating personnel on best practices, and ensuring adherence to regulatory standards cannot be overstated. They serve as a critical component in the pursuit of a safer, more efficient, and compliant maintenance environment. Maintenance managers and team leaders are encouraged to either adopt or refine their approach to toolbox talks, focusing on the long-term benefits they bring in terms of safety and compliance. Continuously evolving these talks to meet the specific needs of their teams — and staying abreast of the latest safety standards and technologies — can significantly enhance the overall safety and efficiency of their maintenance operations. ABOUT THE AUTHOR Sanjay Murthi works for SMGlobal. SMGlobal's FastMaint CMMS software is a powerful & easy-to-use maintenance management software program used by customers worldwide to manage facility and equipment maintenance.
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Manufacturing Showcase
Global Shop Solutions Get ERP Software Right the First Time By Dusty Alexander – Director of Marketing, President & CEO of Global Shop Solutions
M
anufacturing in the U.S. is getting tougher all the time and the pressure is unrelenting. To remain competitive, you must continually cut costs, increase productivity and improve quality, while at the same time offering better service, faster delivery and lower prices. Fortunately, there is a tool to help you accomplish all this and more. By now you’ve probably heard all about ERP software, the approach that cuts costs and boosts productivity by integrating all your production processes into one cohesive system. You’ve probably heard that it can improve on-time deliveries and inventory control while simultaneously reducing administrative overhead. That it can simplify all of your manufacturing processes by increasing visibility throughout the organization. And that it can turn inefficient companies with high cost structures into lean, mean operations that can compete with anyone in the world. The fact is, ERP can do all this and more — we have seen it happen time after time. But to some, the stories sound too good to be true. So you wonder: can ERP really work in my
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business? If so, how do you find the right system, what does it take to install it and what kind of return on investment can you expect? From an operational standpoint, how long does it take to get ERP up and running in a company, and how much training is involved? What steps are required to implement ERP software, and who needs to get involved in the process? Most of all, can ERP software actually deliver on all that it promises to do? If you’re considering ERP software for your business, these are legitimate questions. ERP can literally transform a manufacturing business, but only if you do it right. At Global Shop Solutions, we’ve been doing ERP right for over 40 years. During that time, we have conducted thousands of successful ERP implementations with companies from five to 1,000 employees. In fact, we have the largest number of successful implementations in our market — nobody else is even close. In the process, we’ve learned a great deal about what works and what doesn’t work, and our whole purpose with this booklet is to share some of those lessons with you.
IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
Every company faces different challenges and has different needs in regards to ERP, so there is no cookiecutter solution for implementing the software. However, we have found that certain basic principles apply in nearly every situation, and that following these principles will greatly increase your chances of a successful implementation. So if you’re ready to take your business to the next level, here are nine things you need to know to successfully implement an ERP system right the first time in your company. But first, let’s review exactly what an ERP system involves.
What Is ERP? First developed in the 1970s, ERP software started out as a few unrelated programs slapped together to improve various parts of the manufacturing process. The very best ERP systems evolved into highly comprehensive, fully- integrated software systems that enable companies to manage the entire manufacturing process from one central location while simplifying operations and improving productivity in ways that were previously not possible. In essence, ERP software serves as a central communication point, or hub, for all the activities in a manufacturing business. It consists of different modules that handle everything from estimating, quoting, work orders, all the way to final delivery and billing. ERP also handles all the financial aspects of work generation, including purchasing, inventory management, administrative overhead and all the accounting and financial activities. The end result is a software system that integrates all the essential activities of the business into one nice, neat electronic package. Ideally suited for aerospace and defense firms, sheet metal fabricators, machine shops, screw machine shops, machine builders, electronics and repair facilities, wood shops, medical instrumentation and store fixture manufacturers, ERP allows companies to: » Estimate, quote and bid » Generate sales and purchase orders » Generate work orders » Purchase raw materials, outside resources and services » Schedule people, resources and equipment » Track work in progress » Monitor and manage inventory » Manage the shipping and delivery process » Generate invoices and track accounts receivables » Eliminate all manual spreadsheets and databases The benefits of using ERP software include faster cycle times, better on-time delivery rates, reduced administrative overhead, lower labor and materials costs, improved productivity and more. ERP also enables companies to manage the numbers in real time (instead of at the end of the month or quarter) so that management can make better decisions for the long term. When properly implemented, ERP acts like a company-wide, ongoing process improvement tool that empowers the entire organization to become leaner, more efficient and, ultimately, more profitable.
1
ASSEMBLE A CROSS-FUNCTIONAL ERP TEAM Contrary to popular opinion, selecting, purchasing and implementing an ERP system should not be left solely to the IT function. In fact, if you do you’ll almost certainly fail. ERP software is an interrelated tool that touches every aspect of your business. In addition to simplifying all your mission-critical processes, the software has strategic capabilities that go far beyond merely helping to manage inventory more effectively or schedule jobs more accurately. For many companies, ERP will literally change the way you do business. ERP is more of an approach to better managing your business than a software program. As such, the decision to implement ERP software is a strategic decision that requires the input and unequivocal support of the entire management team, not just the IT function. As part of the team, your IT person plays an important role in the process, especially with regard to all network and hardware issues. To ensure success, however, all decisions regarding the purchase and deployment of an ERP system should be made by a cross- functional team that represents operations, purchasing, accounting, scheduling and all the essential activities of your business. Once assembled, the ERP team has responsibility for: » Researching, evaluating and selecting the appropriate ERP software package » Setting specific goals and objectives (such as improved on-time delivery, better inventory management) for the ERP initiative » Working with the ERP vendor to create and execute an implementation plan » Communicating the need for the ERP software and the benefits to the company and employees » Following through on the plan and holding people accountable When setting goals and objectives, be as specific as possible. For example, “improve on- time delivery by a minimum of 50 percent” will yield better results than the more generic “improve on-time delivery.” Specific goals lay a solid foundation for the implementation process and provide direction for the key decisions that must take place. More importantly, they provide tangible performance metrics with which to measure the success of the implementation and your return on investment. Be sure to recognize this group for a job well done after the ERP system is up and running well. This is a group of true leaders who have successfully implemented a significant change in your business.
2
CHOOSE THE RIGHT SOFTWARE FOR YOUR BUSINESS With so many different ERP systems to choose from, identifying the right software package can be a daunting and time-consuming task. However, given the cost, integration and long-term impact of ERP systems, you need to invest as much time in the evaluation process as possible. INDUSTRIAL MACHINERY DIGEST.COM
IMD | 27
The best approach involves using one of several online tools to sift through all the different vendors and narrow the list down to three to five finalists. Once you have a short list of finalists, conduct extensive interviews with each company and “demo” their software to see which one best fits your needs. Be sure to ask each company to come to your location for a test run. When evaluating different packages, look for the “four C’s” of an ERP system: 1. Complete. The software should integrate all aspects of running a manufacturing business, everything from bidding on jobs to purchasing and materials management to invoicing accounts receivables and producing financial statements. Anything short of that and you’ll wind up with a cobbled together system with bolted on subsystems that may or may not work as intended. 2. Comprehensive. Look for software that incorporates the latest technology and offers the most advanced features and menu options, but is also intuitive and easy to use. One of the easiest ways to assess a system’s ease of use is to spend time moving through the system’s screens. Are the screens visually uncluttered? Does the system’s flow make sense intuitively? 3. Customizable. The software should allow users to create custom reports and use a variety of custom options without requiring vendor modifications to the software. Make sure the system has easy customization features built in from the start. 4. Cohesive. Some ERP systems are actually a series of different software programs patched together into one package. The best ERP softwares are written from the ground up by the same company, so that all the different functions work together as an integrated system rather than a patchwork of loosely-connected programs. In addition, ERP software should be: » Flexible. The software should adapt to the way you do business. If it requires you to change your structure or mode of operations, look for another product. » User friendly. Menu items should be self-explanatory, and the screen layout should make it easy for users to navigate. Learning and using the software shouldn’t require extensive reading of user manuals. However, the software should include a detailed online help system that makes it easy to find the desired information. » Fully integrated. When you make a change at one point in the system, the software should automatically make the change throughout the entire system. Do not invest in software that requires you to manually input the same change on multiple screens. Finally, select a software that is strong at your weakest point. For example, if scheduling represents your biggest bottleneck, make sure the software has a robust scheduling module. Although most ERP softwares offer similar features and functions, some are stronger in certain areas than
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others. When conducting your research, look for an ERP system that delivers maximum performance in your areas of greatest need.
INVEST AS MUCH TIME IN THE EVALUATION PROCESS AS POSSIBLE.
3
CHOOSE THE RIGHT ERP PARTNER With ERP, you’re buying more than just a software package. You’re engaging in a long-term relationship with a business partner that will impact the future success of your company. Investing the time up front to evaluate the vendor as carefully as the product, will pay substantial dividends in the long run. When evaluating the company, pay close attention to three key areas: 1. Company history. The best ERP companies have a proven track record of successful implementations, longevity within the industry, and stable ownership. When evaluating the company, ask: » How long has the company been in business? » Has it acquired or been acquired by other companies? If so, how many times? » What is the structure of the current ownership? How long has it been in place? » How many successful implementations has the company completed? 2. Consultant experience. The consultants who will install the software, conduct the training and guide the implementation are critical to your success. Extensive hands-on experience in manufacturing is paramount to successful implementation. Carefully scrutinize their backgrounds and experience by asking: » How long have the consultants been with the company? » How many successful implementations have they completed? » Have they worked in a manufacturing company or is their experience limited to the software/ technology environment? » Do they have hands-on experience in scheduling, materials management, inventory control and other critical areas? » Will they take the time to understand your business goals and objectives? 3. Culture. How the company does business and interacts with customers will have a direct impact on the success of your implementation. To evaluate the culture, ask: » Are the people friendly and personable? » Do they take the time to learn about your business and the unique challenges you face? » Do they respond to all questions in a timely and positive manner? » Is service and support an integral part of the company or is it outsourced? » Do they have a strong R&D function that is driven by the manufacturing expertise within the company?
» Are they committed to your success? Will they take the time to understand your business goals and objectives? When evaluating an ERP vendor, check several references. Visit with current users to see how they are using the software, what problems they have encountered, and how the vendor has responded to those problems. Don’t leave without asking one critical question: “If you had to do it all over, would you work with this vendor again?”
4
PROVIDE FULL MANAGEMENT SUPPORT Without question, the most critical aspect of any ERP implementation is getting senior management on board and committed to the process. ERP requires a substantial change effort for most companies, and if you and your management team are not fully committed to making it happen, results will fall short of expectations.
WHAT DOES MANAGEMENT COMMITMENT LOOK LIKE? This doesn’t mean that you have to attend every meeting or become an expert in the system. However, your active participation will send a strong message to employees about the importance of the initiative and your support for the software. Bottom line — if you support the new system in an active and visible manner, people will follow your example. If you don’t support it, people won’t use it. In larger companies, management support requires the ongoing involvement of the entire management team, especially those who head critical functions such as purchasing, materials management, inventory management and accounting. Each department head must communicate to his or her team members, model using the system, and hold people accountable for learning and using their specific areas of the software. It also helps to have an ERP champion, or “enforcer,” someone who lays down the law with respect to the implementation process. In smaller companies, this is often the owner or CEO. In larger companies, the CEO typically delegates the role to a trusted senior manager. Regardless of who fills this critical role, it must go to someone in the company who knows how to make things happen and has a track record of getting results. If you delegate this role to one of your direct reports, make sure you give them the full authority and resources they need to get the job done.
5
GET EMPLOYEE BUY-IN Even when people know that change is necessary and/or good for them, they will often resist to some degree. Therefore, every successful ERP implementation must include a concerted effort to get employees to buy into the new system. Start by expecting some resistance to occur, then seek to understand the reasons. For example, some people — especially those who have been on the job a year or more — may resist simply because it feels more comfortable doing things the old way. Others may feel the current system is working fine, so why fix what isn’t broken? A few may consider ERP an invasion of their turf and resist out of fear and/or company politics. The more you know about why people resist the change, the better you can address their issues and improve your chances of a successful implementation. To make the change more attractive to employees and encourage their buy-in: » Communicate the need for the change. Explain how ERP will make their jobs easier and how the company will benefit as a whole. At the same time, point out how difficult it will be for your company to remain competitive without it. » Demonstrate your commitment and support. When staff members see that management is fully behind the initiative, they are more inclined to support it. » Get people involved. Insist that people take ownership of the process. Tell employees, “We’re depending on you to learn this because we’re going to come to you with our questions.” » Assign specific tasks and responsibilities. Often, resistance is due to a fear of the unknown. When people know what is expected of them and what they are responsible for, they will more readily embrace the change and move forward. INDUSTRIAL MACHINERY DIGEST.COM
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Above all, hold people accountable for learning the system and using it. If you pay lip service to the initiative but fail to follow through, people will quickly conclude that you don’t mean business and will go back to using the old system.
6
HAVE A WRITTEN IMPLEMENTATION PLAN (Hint: here’s a key point to look for when evaluating vendors. A good vendor will insist that you have a plan and will work with you to create it.) Why is a written plan so important? Because it removes much of the ambiguity from the process, establishes deadlines for achieving key milestones, and provides a tool for ensuring that all individuals and departments stay on track. In addition, a written plan serves as both a guidepost and a guiding force behind the implementation. An effective ERP implementation plan can be done in spreadsheet format in one or two pages. It should: » Identify all technical issues that need to be addressed by IT » Include all goals and objectives » Assign specific tasks and responsibilities to individuals and departments » Set deadlines for important milestones such as data conversion, training schedules and data testing » Establish a firm “Go Live” date Many companies also use an implementation audit to track progress against the plan. In fact, the best ERP vendors will provide you with their own audit form and insist on receiving your feedback. These audits typically ask questions related to the general areas of security, menu, help, training and conversion, as well as specific modules such as inventory, estimating and operations. They provide an excellent tool for measuring how well people are learning and understanding the software during the training phase and for identifying potential bottlenecks in the implementation process. A good implementation plan starts with realistic goals. For example, don’t expect to buy the software in the middle of November and go live with it on January 1. Also, take into account the various workloads of departments and employees when setting up the implementation timeline. Overloading people who are already working at full capacity will raise stress levels and the resistance to the change. As much as possible, schedule training and implementation around work, rather than in place of it. Finally, keep in mind that no plan — no matter how well written — unfolds without some adjustments. With ERP, the most successful implementations are those that follow the steps from start to finish, even if the timeline gets a bit off track. If minor bumps occur, stick to the components of the plan as much as possible, but be prepared to tweak the timeline to accommodate circumstances that may arise.
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7
SELECT THE RIGHT IMPLEMENTATION APPROACH There are two basic ways to implement ERP software, the Phased-In Approach and the Big Bang Approach.
THE PHASED-IN APPROACH The phased-in approach implements the software one or two modules at a time, generally starting with the areas that need the most improvement. This gives users more time to train on the software and get comfortable with it before going live. It also puts less pressure on the organization as a whole, as not everyone is required to learn the software and go live at the same time. Lastly, it can also first address the areas of your organization that have the greatest inefficiencies and, therefore, produce the fast gains and early successes. The disadvantages with the phased-in approach are that it can allow users to procrastinate learning the system, and it sometimes pits one group against another. For example, those required to learn the software may resent the extra work, while those not using it may feel left out.
THE BIG BANG APPROACH With the big bang approach, everyone trains on the new system at the same time and the data gets converted all at once. On the appointed date to go live, you literally unplug the old system and plug in the new. The advantages? Everyone gets involved, plus you integrate all the systems at once rather than over a period of time. This approach also cuts down on procrastination. Perhaps most important, it creates a shared experience within the company as everyone learns the system together and works to make the implementation a success. Drawbacks to the big bang method include having less time to test the data and experiment with the system before going live. Plus, if key people fall behind or miss training, it can force postponement of the go live date, which can stall momentum and enthusiasm for the project.
Which implementation approach is right for you? That depends on several factors, including the time frame for the implementation and the amount of people and resources you can commit to the project. A good consultant will make a recommendation based on his or her understanding of your company’s needs. However, the final decision should always rest with your implementation team. Regardless of which method you choose, the actual implementation requires four basic steps: preparation, converting the data, training/testing and going live. Each step should have specific timelines for completion and someone accountable for ensuring those deadlines are met. Keep in mind, however, that implementation is a fluid process that requires adapting to different circumstances as they arrive. So plan thoroughly, implement carefully, and be prepared to adjust when necessary.
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UTILIZE TRAINING OPPORTUNITIES When it comes to training employees on the new ERP system, there are two critical questions immediately arise: » How much training is required for a successful implementation? » How much should you budget for the training? As a rule of thumb, you can never have too much training, especially when embarking on a big bang implementation approach. ERP is a sophisticated system, and people need plenty of time to learn the product, experiment with it and see how it works before actually going live. Granted, the best ERP applications are intuitive and easy to use, but proper training goes beyond the basic software so that people can utilize all the features and maximize your investment in the system. The second question is not so easily answered. How much you budget depends on the size of your company, the number of employees who will use the product, and their knowledge base regarding the software and computers in general. Generally speaking, smaller companies will pay less for the software, but more for training. As the companies get larger, the cost of training as a percentage of total cost goes down. Once you get to 15+ users, a training budget equal to 25 percent of the software cost represents a realistic minimum. Regardless of cost, the best ERP companies offer three different types of training: » Vendor-based. Your employees go to the vendor’s site for an intensive crash course in the software. This typically involves the first round of training and generally lasts three to five days. » On-site. The vendor comes to your site to work with specific groups and/or individuals. This training can last one or more days and usually involves some of your own data. » Online. This can include online tutorials as well as subscription classes with a live instructor. The classes generally run one to two hours and cover specific areas of the software. In particular, the subscription classes can help employees get up to speed quicker and use more of the system once you go live. They’re also good for second and third generation employees, so that outgoing workers do not have to train their replacements. Finally, recognize that training should not end with implementation. Bringing in onsite instructors once a year will enable new and existing employees to use the system much more effectively, which enhances your ongoing return on investment.
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PUTTING IT ALL TOGETHER Ultimately, the success of any ERP implementation depends on three critical factors: firm support from senior management, a written plan with clearly defined
goals, timelines and responsibilities, and a comprehensive training schedule that includes vendor-based, onsite and online training. Follow through on these three areas and you’ve won 95 percent of the battle. For the remaining five percent: » Choose your priorities carefully. Most companies do 80 percent of their business with 20 percent of their customers, 20 percent of their vendors and 20 percent of their part numbers. If you plan to convert your data a little at a time, start with the 20 percent that will yield 80 percent of your results. » Don’t waffle on the “Go Live” date. People need deadlines to hold them accountable. If you extend the date because people aren’t ready, they will continue to procrastinate. When you set a firm “go live” date and stick to it, people will learn the system. » Avoid the “super user” syndrome. Don’t depend on one highly motivated employee to become expert on the software and then teach it to others. This approach ensures a delayed implementation at best and outright failure at worst. » Keep the momentum going. Avoid stops and starts in the implementation process at all costs. Once people get excited about using the system, it’s better to keep the momentum going, even if you only implement a little at a time. Finally, accept the fact that you will never find a perfect time to implement ERP. If business is slow, you may not want to spend the money for thorough training. If the business is growing rapidly, employees may feel they don’t have the time to do their regular jobs and take on something new. The bottom line is that ERP involves a giant step forward to position the company for sustained growth and profitability. Keeping this end goal in mind will make it easier to endure the growing pains that inevitably arise when undertaking organizational change. If you decide to implement an ERP system, we hope you choose Global Shop Solutions. Regardless of which system you choose, we hope it exceeds your expectations. If you have any questions about Global Shop Solutions or about ERP software in general, please email marketing@gssmail.com.
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Automation & Robotics
Introducing TwinBox: RoboDK’s Compact Solution for Production Robot Integration
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oboDK TwinBox represents the latest step in production robot programming for automation engineers. This compact system, launched in November 2023, integrates pre-installed RoboDK software into industrial PCs and small single-board computers or IPCs. RoboDK TwinBox can manage multiple devices and robots from various manufacturers simultaneously in a production environment. Robot simulation software company, RoboDK, recognized the need for a more compact and versatile solution that doesn’t rely on
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conventional computers. Following customer demand for such a product, they created TwinBox. This self-contained system offers a full suite of features that enable users to easily set up and manage robotic systems in their workspaces using a simple single-board computer or IPC. TwinBox can be easily controlled through a web browser, allowing you to trigger actions remotely and have a 3D view of your cell. Dmitry Lavygin, software developer at RoboDK, says, “RoboDK is already able to run programs directly on real robots using its online mode and robot drivers. However, it is not common to see desktop or laptop computers in production environments. The goal with TwinBox is to provide a dedicated version of RoboDK for industrial computers and enable remote control on embedded devices, without the need of a local display, keyboard, or mouse. You can simply control the system remotely
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from anywhere, using your browser or another remote RoboDK connection”.
The need to minimize clutter and save space with production robots The team at RoboDK conceived TwinBox after identifying a gap in the market – there were no space-efficient solutions for production engineers wishing to directly implement RoboDK into the production line. The product’s compact size offers the advantage of easy positioning – it can be installed either next to or within the factory robot’s control system. A key feature of the TwinBox is its ability to function effectively without the need for a mouse, keyboard, and monitor. It solely requires network interfaces to seamlessly connect to an internal network and a robot control system. This allows users to save more of their valuable floor space while still being able to utilize the full suite of features that RoboDK has to offer. TwinBox is an all-in-one solution for robot programming and automation engineers, with many benefits including its compact size, low cost, easy setup, and versatility.
Remote robot programming built on reliable technologies RoboDK’s approach to product development is to build
new solutions on the back of tried and tested technologies, where possible. This means the company can deliver high-quality remote robot programming solutions without compromising on reliability or stability. With TwinBox, RoboDK has crafted a reliable system that runs on both industrial and consumer-grade hardware. It supports multiple operating systems and hardware architectures, including Windows and Linux Debian or Ubuntu running on Intel x86-64 platforms or ARM. RoboDK provides dedicated builds for systems such as the Nvidia Jetson or Raspberry Pi-based industrial computers. Samuel Bertrand, software developer lead at RoboDK, says, “The software works just like the Desktop version of RoboDK. The main difference is that the system can be controlled remotely from any browser.”
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With its remote interface, users can also access their TwinBox from anywhere in the world, with full control of all connected external robots, devices, and sensors. This allows users to monitor their robots remotely, in real-time, giving them more flexibility and control over their automation than ever before.
Streamlining Multiple Devices into One Cohesive System A common challenge with industrial robots is that each programming solution is often limited to a single manufacturer. This means that each robot brand needs to be programmed separately, which slows down deployment. With TwinBox, users can connect multiple robots from different manufacturers together into one cohesive system. This increases flexibility and significantly speeds up the integration process. RoboDK already supports over 1000 robot models from over 50 brands. This wide compatibility means that users can be sure that their TwinBox will work with almost any robot model they need it to. The system is also designed to effortlessly handle simultaneous connections from varied devices. This includes not only robots but also additional devices like external sensors and computer vision cameras. TwinBox enables simultaneous connections, allowing you to control it from a remote desktop with a browser. It also “supports” OPC-UA and RoboDK will be implementing other industrial protocols.
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The company plans to incorporate TwinBox into the larger RoboDK ecosystem. This includes existing solutions like the main RoboDK Desktop application as well as web-based development tools like RoboDK for Web. This integration will enable users to take full advantage of all the features that have made RoboDK such a popular robot programming software among automation engineers. The potential applications for TwinBox are virtually endless. The company hopes that users will take full advantage of the product to easily build efficient robotic solutions that can be easily deployed in production environments.
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ABOUT ROBODK Founded by Albert Nubiola in January 2015, RoboDK is a spin-off company from the highly prestigious CoRo laboratory at ETS University in Montreal, Canada. RoboDK software is designed to bring powerful robotics simulation and programming capabilities to companies large and small and to coders and non-coders alike. Today, it supports more than 1000 robots from over 50 different manufacturers, including ABB, Fanuc, KUKA, Yaskawa/Motoman, Stäubli, Omron, and Universal Robots.
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Workforce Development
SME Launches Training and Electric Vehicle Certification to Address High and Unmet Demand for Electrification Skills Designed for Positions Working with Electric Vehicles and E-Mobility
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ME, the nonprofit committed to accelerating new manufacturing technology adoption and building North America's talent, has expanded its capabilities to serve the quickly-evolving talent needs in the electrification market today with new training and an Electric Vehicle (EV) Fundamentals certification. This expansion builds upon SME’s long history serving the automotive industry’s talent needs, as well as accelerating technology advancements such as additive manufacturing, automation, and SMART manufacturing. EVs are expected to make up 50% of auto sales by 2030; potentially creating over 150,000 new jobs related to the production and maintenance of electric cars, according to the Economic Policy Institute. Additionally, the growth of EVs is also likely to spur job creation across the broader electrification ecosystem. According to a report published by the nonprofit Rewiring America, it is estimated that the U.S. can create some 25 million jobs by 2035 if the economy moves on from fossil fuels to electrification. It is predicted that as charging infrastructure expands and electricity generation shifts toward renewables, new roles will emerge to support the transition to cleaner transportation. As a nationally recognized certifying body for over 50 years in manufacturing, SME obtained input from industrial and academic experts to develop a Body of Knowledge that encompasses the technologies, job roles, competencies, and skills critical to the electrification industry. The training roadmap takes learners through broader manufacturing areas that are foundational to automotive assembly, electric vehicle production, and e-mobility manufacturing. In addition, electrification-specific training is designed to incorporate key learning objectives to prepare learners
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whether individuals have no background in vehicle production and assembly, or they have experience but need to tailor their knowledge to the EV market. Topics like lithium battery handling and safety, high-energy batteries, and electric vehicle components and manufacturing are covered in-depth. The training, along with the certification, prepares individuals to thrive in a variety of job roles, including assembly technician, production associate, team assembler, manufacturing technician, battery pack assembler, quality control inspector, electric motor assembler, and maintenance technician. SME's efforts to upskill workers for electric vehicle manufacturing include support from industry groups and states; especially those with heavy concentrations of automotive companies. "The Michigan Manufacturers Association (MMA) applauds SME’s national launch of curriculum and industry-recognized certification supporting individuals working in the assembly and production of electric vehicles,” said MMA President and CEO John J. Walsh. “And as a partner with the SME Education Foundation on expanding the SME PRIME school network to at least 49 Michigan high schools by 2025, we excitedly anticipate
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the integration of the new curriculum and credentials into PRIME’s career pathways for students.” “To ensure all of North America’s talent has the capabilities needed to adopt new technologies and advanced manufacturing, SME has undertaken extensive research into labor demands for EV manufacturing and electrification, including leveraging insights from industry leaders,” said Jeannine Kunz, SME’s chief workforce development officer. “Our collaboration with manufacturers, schools, and workforce organizations will embed in-demand EV expertise and competencies into nationwide career development programs and technical education.” Based on the rising national demand, states are seeing the need to prepare for this emerging industry, including South Carolina, the number one passenger vehicle exporter in the U.S. The state’s automotive industry employs 75,000 and has seen an overall $9.6 billion capital investment from automakers and suppliers in the EV industry since 2017 according to the South Carolina Department of Commerce. “The success we envision as a state in the electric vehicle industry hinges not only on cutting- edge technology but also, and even more crucially, on developing a skilled workforce,” said Brad Neese, vice president, South Carolina Technical College System – Division of Economic Development. “A talent pipeline that is skilled and ready to work serves as the driving force towards achieving our goals.” 2022 IMD AD final 11-21-2.pdf 1 11/22/22 12:16 AM Similarly, Michigan is focused on upskilling its workforce
to maintain leadership in automotive manufacturing amid the transition to electric vehicles. "There’s no denying that Michigan, which is home to nearly 19 percent of all U.S. auto production and over 60 percent of the country’s mobility and vehicle R&D spending, is a powerhouse of automotive manufacturing and innovation,” said Walsh. “As the auto industry’s transition to electrification accelerates, the need for workers with EV-related skill sets is increasingly critical to Michigan’s leadership position in the automotive and mobility space.” “With EV technology revolutionizing the automotive industry, there is a unique opportunity for thousands of individuals to harness its potential into a promising career,” said Robert “Bob” Willig, executive director and CEO of SME. “SME’s strong partnerships with industry and education, commitment to advancing emerging technologies, focus on upskilling the nation’s workforce and dedication to validating competency through certification will all contribute to supporting the evolution of U.S. manufacturing in this way.” SME is committed to supporting the industry's transition to battery electric vehicles (BEV) and will remain dedicated to closely evaluating the evolving needs of the industrial and educational spheres. As a nonprofit whose purpose is to advance manufacturing to drive competitiveness, resiliency and national security, SME will actively identify upcoming challenges and opportunities to position North America at the forefront of electric vehicle design and production.
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New Technology
Siemens Revolutionizes Engineering Simulation with HEEDS AI Simulation Predictor and Simcenter Reduced Order Modeling
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mbarking on the forefront of engineering innovation, Siemens Digital Industries Software introduces two groundbreaking solutions poised to redefine the landscape of simulation technology. The HEEDS AI Simulation Predictor emerges as a catalyst, empowering organizations to unlock the full potential of their digital twin. Through cutting-edge AI equipped with inherent Siemens' HEEDS AI Simulation Predictor empowers organizations to take full advantage of the digital twin to optimize products accuracy awareness, through advanced state-of-the-art AI with built-in accuracy awareness (Image credit: Siemens Digital Industries Software) product optimization becomes an art form. The journey continues with Simcenter Reduced Order Siemens Xcelerator portfolio, it can revolutionize design Modeling, seamlessly blending high-fidelity simulation and space exploration. test data to train AI/ML models, resulting in predictions made in mere fractions of a second. Together, these Key Advantages: advancements promise not only speed and precision but » Optimize products with precision: HEEDS AI Simulation also a paradigm shift in the way we approach and elevate Predictor harnesses state-of-the-art AI with built-in the field of engineering simulation. accuracy awareness helps organizations to fully Siemens Digital Industries Software today set the leverage the digital twin to fine-tune and optimize their benchmark for innovation in the field of engineering products with unprecedented precision. simulation with the launch of two groundbreaking » Faster, more innovative designs: By tapping into solutions - HEEDS™ AI Simulation Predictor software and historical simulation studies and accumulated Simcenter™ Reduced Order Modeling software. These tools knowledge, engineering teams can swiftly craft empower engineers to tackle the most complex challenges high-performing, innovative designs, significantly manufacturers face, delivering predictive performance with reducing time-to-market. speed, precision, and efficiency. Siemens' HEEDS AI Simulation Predictor unlocks Addressing the AI drift challenge new possibilities for manufacturers by empowering One of the most significant challenges in AI-powered engineering teams to harness the potential of advanced simulation is AI drift, where models extrapolate AI-driven predictive modeling. As a new addition to the inaccurately when faced with uncharted design spaces.
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To address this challenge, HEEDS AI Simulation Predictor introduces accuracy-aware AI. This new technology actively self-verifies predictions, aiding engineers to conduct simulations that are not only accurate but also reliable in the context of real-world industrial engineering applications. "With HEEDS AI Simulation Predictor, we have significantly improved various components of the gas turbine, leading to highly optimized designs and accelerated design cycles," said Behnam Nouri, Team Lead, Engineering & Platform Design, Siemens Energy. "Our thermomechanical fatigue predictions have been effectively upgraded to process ~20,000 design members in only 24 hours, yielding a 20% improvement in component lifetime. This has allowed us to fully characterize the limits of our existing design space which is required for high-efficiency turbine engines. The HEEDS AI Simulation Predictor technology has enabled us to save over 15,000 hours of computational time." Siemens today also introduces Simcenter Reduced Order Modeling, new software that harnesses high-fidelity simulation and test data to train and validate AI/ML models. These models then enable engineers to perform predictions in a fraction of a second, transforming the way engineering professionals approach simulation.
Siemens Digital Industries Software. "It also enables them to not only use these breakthrough technologies on new projects, but to leverage decades of past simulation data to help deliver new insights on current projects."
Key Advantages:
Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI's unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 71,200 employees internationally.
» Speed and precision: Simcenter Reduced Order Modeling uses high-fidelity data to empower engineers to gain rapid predictions and to make critical decisions in a fraction of the time it would take using conventional methods. » Predictive performance: By training AI/ML models on comprehensive datasets, this technology enables engineers to gain robust, reliable, and trustworthy insights, helping to eliminate the common issue of AI drift. "Simcenter Reduced Order Modeling lets us accelerate our simulation models to the point where a detailed fuel cell plant model runs faster than real time, with the same accuracy as a full system model," said Jurgen Dedeurwaerder, Simulation Engineer, Plastic Omnium. "This enables activities such as model-in-the-loop controller development and testing to be done faster, shortening the overall development cycle by around 25%. At the same time, it gives us a reliable, IP protected, and cost-effective way to distribute models to other teams, both internally and to our customers to augment their own products and processes, resulting in better quality products delivered to end users." "HEEDS AI Simulation Predictor and Simcenter Reduced Order Modeling represent a true breakthrough in simulation technology. They enable our customers to take advantage of benefits of artificial intelligence-driven simulation to speed their exploration of a design space and to do so accurately and robustly," says Jean Claude Ercolanelli, Senior Vice President, Simulation and Test Solutions at
For more information: To learn more about how Siemens Digital Industries Software is making a significant leap forward in the quest for reliable, trustworthy AI-driven simulations and pushing the boundaries of what's possible in simulation technology, visit the What's new in HEEDS and Simcenter Reduced Order Modeling blogs.
ABOUT SIEMENS DIGITAL INDUSTRIES SOFTWARE Siemens Digital Industries Software helps organizations of all sizes digitally transform using software, hardware and services from the Siemens Xcelerator business platform. Siemens' software and the comprehensive digital twin enable companies to optimize their design, engineering and manufacturing processes to turn today's ideas into the sustainable products of the future. From chips to entire systems, from product to process, across all industries. Siemens Digital Industries Software – Accelerating transformation.
ABOUT SIEMENS DIGITAL INDUSTRIES (DI)
ABOUT SIEMENS AG (BERLIN AND MUNICH) Siemens AG (Berlin and Munich) is a leading technology company focused on industry, infrastructure, transport, and healthcare. From more resource-efficient factories, resilient supply chains, and smarter buildings and grids, to cleaner and more comfortable transportation as well as advanced healthcare, the company creates technology with purpose adding real value for customers. By combining the real and the digital worlds, Siemens empowers its customers to transform their industries and markets, helping them to transform the everyday for billions of people. In fiscal 2023, which ended on September 30, 2023, the Siemens Group generated revenue of €77.8 billion and net income of €8.5 billion. As of September 30, 2023, the company employed around 320,000 people worldwide. Further information is available on the Internet at www.siemens.com. INDUSTRIAL MACHINERY DIGEST.COM
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Process
Four Predictions for 2024: AI Set to Supercharge Robotic Automation By Anders Billesø Beck, VP of Innovation and Strategy at Universal Robots
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e’ve reached that point in the year when it’s time to reflect upon the trends from the past 12 months, while looking ahead at what 2024 has in store for the world of robotics and automation. 2023 was an exciting year for innovation. The emergence of artificial intelligence (AI) technologies, such as generative AI, captured global attention and dominated headlines. However, the adoption of generative AI for businesses is still very much in its early stages and questions around how best to harness this technology remain at the forefront of many minds. Digital transformation is an ongoing process so we can expect to see this year's breakthrough trends continuing to shape society into next year. But how will these trends impact robotics and automation and what can the manufacturing industry expect to see next year?
1
AI WILL SET A NEW PACE OF DEVELOPMENT IN ROBOTICS AND AUTOMATION AI is transforming the world of software development, making it cheaper, faster, and more effective. Software is a key component of automation, and with AI, software developers will be able to create more customized and optimized solutions for various tasks and challenges. If software development has sometimes felt like digging with a shovel, the introduction of AI is like bringing two horses and a plough to the process. However, automation expertise will remain a scarce and valuable resource in the process of AI revolutionizing manufacturing. It has been interesting and perhaps surprising to see AI changing the lives of office workers before it touches working practices in most factories. I look forward to seeing the benefits of machine learning reach more manufacturers in 2024. After all, the technology is already there – we have many partners developing applications using AI to allow our robots to perform more complex and diverse functions. For example, AI allows robots to have human-like perception, handle variation, move parts precisely, adapt to changing environments, and learn from their own experience. With time, these capabilities will lead to unprecedented flexibility, quality and reliability in manufacturing.
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2
DEVELOPMENTS IN ROBOTICS SOFTWARE WILL ENABLE MORE SHARING AND REUSE Robotics software is the glue that binds users to their mechanical counterparts - a digital connectivity that transcends physical interaction. Software developments are enabling a new dimension of collaboration - connecting the people that use robots. 2024 will see software developments leading to new levels of sharing and reusability. Imagine a world where, instead of reinventing the wheel, we leverage existing software assets—components, interfaces, algorithms—across multiple applications. It’s a principle that already underpins our UR+ partner ecosystem, streamlining innovation and reducing time-to-market. I can’t wait to see this evolve next year.
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COMPANIES WILL FUSE IT AND OT USING DATA TO IMPROVE OPERATIONS The future of manufacturing is intricately linked to IT/OT integration as data will underpin innovation and efficiency. Research shows that the manufacturing industry has been at the forefront of adopting cloud-based software services and we are already seeing some customers use these to enhance quality, cost efficiency, and predictability. That makes me confident that 2024 will see the growth of data-driven logistics and manufacturing systems. Many still have an outdated view of the cloud merely being a data collector and backup function, as we know
IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986
if from our private lives. But the real potential and power doesn’t lie in storing data or even in linking machines. The real transformative leap comes when cloud-based software services connect humans and machines and thus help manufacturers simplify complex processes and make smarter decisions. The benefits of this digital evolution are significant. Remote access to manufacturing data enables quick responses to issues and continuous automation improvement. With dynamic systems now essential, trusted cloud technologies offer the latest in security and state-of-the-art services. Industrial Internet of Things (IIOT) companies highlight this progression, promising improved efficiency and reduced downtime through Overall Equipment Effectiveness (OEE) visualization and predictive maintenance. As we approach 2024, manufacturers stand to gain from these advancements, achieving higher quality, reduced downtime, better predictability, and cost optimization. This transition is a strategic necessity, supporting the shift towards high-volume, high-mix production, resilient supply chains, competitive data utilization, and sustainability goals.
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LOGISTICS WILL BE A FOCUS AREA FOR ROBOTICS Earlier this year, Interact Analysis looked at
projected growth rates in robot shipments across industries. The stand-out projected growth area? Logistics, where Interact Analysis put the projected CAGR for collaborative robot (cobot) shipments at 46% for 2023-2027. I’m not surprised as the market for non-industrial applications is growing fast. Like manufacturing, many logistics companies face serious labor shortages while pressure is increasing as a result of globalization, e-commerce and complex multichannel supply chains. More logistics, warehouse and distribution centers will turn to automation next year to provide services faster and with greater accuracy. To take an example - facing the challenge of surging e-commerce demands, one logistics company we worked with revolutionized its fulfilment center with collaborative robots, resulting in a 500% surge in efficiency and order accuracy. The automation system, adept at processing thousands of orders daily, particularly excelled during peak periods, like Black Friday, where a robot managed up to 4,400 orders in one day with just a small crew for replenishment. Robots – and the smart use of data – are poised to revolutionize logistics businesses across the whole value chain from incoming packages to outbound logistics. The pace of development is robotics remains impressive - I look forward with great anticipation to another exciting year of progress.
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Industry Insight
Red Bull Ford Powertrains Pursues the Sustainable Future of Motorsport with Siemens Xcelerator » Red Bull Ford Powertrains is using the Siemens Xcelerator portfolio of industry software to develop a new hybrid power unit for 2026 racing season » Hybrid power unit specifications for the 2026 season require a more even split between Internal Combustion Engine (ICE) and electric power
S
iemens Digital Industries Software announced today that Red Bull Ford Powertrains has leveraged the Siemens Xcelerator portfolio of industry software to rapidly develop the next generation hybrid ICE/ electric driven Power Unit (PU) for the Formula 1 2026 racing season. For the 2026 season, Red Bull Ford Powertrains will build power units for both the Oracle Red Bull Racing and Scuderia Alpha Tauri F1 Teams and will be one of only six manufacturers supplying power units for the F1 series.
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From the announcement of its intent in 2021, Red Bull Ford Powertrains has set an ambitious goal of developing 2026-specification sustainable high-speed power units from the ground-up, while meeting new specifications from F1. Like any start-up, Red Bull Ford Powertrains is breaking new ground with every component design, especially given the lack of historical data, in the extremely secretive world of powertrains development. Ben Hodgkinson, Technical Director, Red Bull Powertrains Ltd said “Siemens Xcelerator is the digital
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backbone of our design and manufacturing journey, enabling us to concurrently engineer hundreds of rapid design evolutions across a large newly formed team; ensuring each designer has visibility and knowledge of what their colleagues are working on. “It is especially challenging as we don’t have the luxury of historical data; every component, down to the nuts and bolts of the engine, has to be modeled from scratch. This means the design quality and ease of use from Siemens’ NX, combined with collaboration and lifecycle management with Teamcenter, is a critical factor for success.” In addition to Siemens’ NX™ software for product engineering and Teamcenter® software for product lifecycle management (PLM), the Red Bull Ford Powertrains team leverages the simulation and test capabilities of Siemens’ Simcenter™ STAR-CCM+™ software to assist with design and validation across the project. “The motorsport industry is aggressively pursuing a cleaner, more sustainable future that requires radical reinvention of how teams and suppliers approach all aspects of their development activities. By leveraging the benefits of digital transformation, delivered through the use of Siemens Xcelerator, we’re able to help motorsport partners in the field with their discovery, invention and ultimately, delivery of new cleaner solutions on the track, where rubber meets the road, in timescales previously thought unattainable,” said Robert Jones, executive vice president, global sales and customer success, Siemens Digital Industries Software. “We are delighted to play a part in the success of the Red Bull Ford Powertrains team in achieving its goal to bring greater sustainability to motorsport and to meet the requirements for fossil carbon free performance, greater use of electric power and energy recovery for the 2026 racing season.” ABOUT SIEMENS DIGITAL INDUSTRIES SOFTWARE Siemens Digital Industries Software helps organizations of all sizes digitally transform using software, hardware and services from the Siemens Xcelerator business platform. Siemens' software and the comprehensive digital twin enable companies to optimize their design, engineering and manufacturing processes to turn today's ideas into the sustainable products of the future. From chips to entire systems, from product to process, across all industries. Siemens Digital Industries Software – Accelerating transformation.
ABOUT SIEMENS DIGITAL INDUSTRIES (DI) Siemens Digital Industries (DI) is an innovation leader in automation and digitalization. Closely collaborating with partners and customers, DI drives the digital transformation in the process and discrete industries. With its Digital Enterprise portfolio, DI provides companies of all sizes with an end-to-end set of products, solutions and services to integrate and digitalize the entire value chain. Optimized for the specific needs of each industry, DI’s unique portfolio supports customers to achieve greater productivity and flexibility. DI is constantly adding innovations to its portfolio to integrate cutting-edge future technologies. Siemens Digital Industries has its global headquarters in Nuremberg, Germany, and has around 76,000 employees internationally.
ABOUT SIEMENS AG (BERLIN AND MUNICH) Siemens AG (Berlin and Munich) is a technology company focused on industry, infrastructure, transport, and healthcare. From more resource-efficient factories, resilient supply chains, and smarter buildings and grids, to cleaner and more comfortable transportation as well as advanced healthcare, the company creates technology with purpose adding real value for customers. By combining the real and the digital worlds, Siemens empowers its customers to transform their industries and markets, helping them to transform the everyday for billions of people. Siemens also owns a majority stake in the publicly listed company Siemens Healthineers, a globally leading medical technology provider shaping the future of healthcare.
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Product Showcase
PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers. WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com
AMADA WELD TECH Introduces SIGMA® LS Laser Micromachining Subsystem AMADA WELD TECH launches the SIGMA LS Laser Micromachining Subsystem, a femtosecond laserintegrated module designed for precise micromachining of various materials. Ideal for machine builders, system integrators, contract manufacturers, and R&D laboratories, the SIGMA LS offers processing versatility for applications such as hole drilling, polymer ablation, ceramic microfluidics, and texturing. The subsystem, featuring pre-installed laser and optical components, ensures optimal quality, minimal thermal effects, and high stability. Available with femtosecond laser options from 5 to 40 watts and both infrared and green wavelength options, it provides an integration-ready solution with on-site support and application training.
EXAIR Unveils PEEK 1/2 NPT Super Air Nozzle™ for Precise Blowoff with Equipment Protection EXAIR introduces the PEEK 1/2 NPT Super Air Nozzle™, designed to deliver robust blowoff without causing damage to sensitive equipment. Constructed from PEEK plastic, it offers non-marring protection to production items and excellent resistance to harsh chemicals and high temperatures. Ideal for blowoff, cooling, and drying applications in general industrial or corrosive environments, the nozzle provides a hard-hitting blowoff while reducing air consumption and ensuring safety. Engineered for easy replacement of existing nozzles in critical applications, it meets or exceeds OSHA standards and is CE compliant.
E-Z Lok Unveils E-Z Sonic™ Inserts and Heat Staking Kits for Thermoplastics E-Z Lok introduces E-Z Sonic™ inserts with Threaded Insert Assortment kits, catering to post-molding
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AMADA WELD TECH Introduces SIGMA® LS Laser Micromachining Subsystem
installation in thermoplastics like acrylic, polypropylene, and PVC. Machined from high-quality brass, these inserts offer durability and versatility with superior torque and pull-out resistance. Available in both inch and metric threads, designs include tapered and straight options, suitable for ultrasonic horn or heat driver installation. Additionally, E-Z Lok presents Heat Staking threaded insert assortment kits, ideal for adding machine threads to 3D printed parts and prototypes, featuring various thread options in tapered and straight designs with imperial and metric threads.
Platinum Tooling Expands Heimatec Live Tool Range for Haas BMT Turret Platinum Tooling, the exclusive importer of Heimatec live tools, has broadened its product line for the Haas BMT turret. The expanded range includes axial and radial driven tools, static tool holders, and specialty tools like multispindle, adjustable angle, and speed multipliers. Recently reengineered, these tools boast higher RPM capabilities, resulting in reduced production time and extended tool
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life. With over 40,000 designs in its database, Heimatec offers immediate support and cutting-edge tooling technology for the BMT turret.
Rocklin Manufacturing Unveils MobiLase® Laser Cleaner for Efficient Surface Cleaning Rocklin Manufacturing introduces the MobiLase® Laser Cleaner, a portable and powerful 100W fiber laser housed in a 60-lb. rolling suitcase. Designed for efficient rust, paint, oil, and dirt removal, the dry laser cleaning process eliminates the need for grinding, blasting, or chemicals. The handheld applicator, weighing only 1.4 lbs., offers precise surface-level cleaning with a short pulse duration and small beam diameter. With simple wireless or offline programming, the MobiLase® Laser Cleaner provides a versatile, user-friendly solution for diverse cleaning applications. Safety features include trigger-activated cleaning, laser glasses, gloves, and optional fume extraction, ensuring a secure and efficient cleaning process.
Siemens Unveils HEEDS AI Simulation Predictor and Simcenter Reduced Order Modeling for Cutting-edge Engineering Simulation Siemens Digital Industries Software introduces two groundbreaking solutions - HEEDS™ AI Simulation Predictor and Simcenter™ Reduced Order Modeling. HEEDS AI
Rocklin Manufacturing Unveils MobiLase® Laser Cleaner for Efficient Surface Cleaning
Simulation Predictor utilizes advanced AI with accuracy awareness to optimize products with precision, leveraging the digital twin for unparalleled accuracy. It accelerates design cycles, providing faster, innovative designs based on historical simulation studies. Simcenter Reduced Order Modeling
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transforms high-fidelity simulation or test data into rapid AI/ ML predictions, offering speed, precision, and predictive performance. Both solutions address challenges like AI drift, ensuring accurate and reliable predictions, marking a significant leap in engineering simulation technology.
Lantek Launches Lantek v43 Software with a Focus on Process Automation and Traceability
Universal Robots Introduces UR30: A 30 kg Payload Collaborative Robot Danish cobot manufacturer, Universal Robots, expands its product range with the UR30, a collaborative robot with a 30 kg payload. As the second model in the next-gen cobot series, UR30 shares the architecture of the awardwinning UR20. Despite its compact size, UR30 excels in lift capacity and motion control, making it suitable for applications such as machine tending, material handling, and high torque screw driving. The higher payload enhances possibilities for using multiple grippers simultaneously, optimizing productivity. UR30's versatility accommodates various industries, supporting agile manufacturing and modularity in production.
Lantek, a leader in digital transformation for the sheet metal and metal cutting sector, has released Lantek v43 software, featuring over 80 improvements. The new version emphasizes process speed and efficiency, offering automatic and intelligent tools for sheet metal manufacturing. It enhances manufacturing and inventory management flexibility, traceability, security, and material optimization. Lantek Expert, part of the suite, streamlines the programming process and allows easy nest reassignment. Lantek Flex3D optimizes performance and reduces downtime, while Lantek Bend improves folding tasks. Lantek MES and Lantek Integra enable agile production planning, inventory optimization, and cost control. The software enhances production scheduling and workload balancing for improved workshop responsiveness.
Palmgren® Introduces Versatile Mill/Drill Machine for Multiple Applications Palmgren, a C.H. Hanson® brand with a century-long legacy, has introduced a versatile Mill/Drill combination machine designed to excel in end milling, face milling, slotting, drilling, and boring applications. This economical machine offers maximum versatility for small job shops, model shops, fabrication shops, and maintenance departments. Constructed from solid cast iron, the Mill/Drill Machine features a precision-ground T-slotted machine table with adjustable feed stops, a hinged belt cover for quick speed changes, and heavy-duty tapered roller bearings to support the spindle. Backed by the Palmgren 3-Year Warranty, this machine is built for durability and performance.
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Movu Robotics Launches Movu eligo Robot Picking Arm to Transform Piece Picking Movu Robotics introduces the Movu eligo robot picking arm, a fully integrated robotic bin picking solution. Developed in collaboration with Righthand Robotics, this innovation automates piece picking from a single-SKU source bin to multiple mixed-SKU destination bins, bridging the gap between manual and fully automatic operations. The Movu eligo achieves reliable robotic picking of up to 600 items per hour, offers seamless integration with the Movu escala bin shuttle, and reduces costs per pick. With intelligent grippers and machine vision,
it ensures accurate and efficient picking, making it suitable for various industries. The robot operates on a plug-and-play API and leverages machine learning for continuous improvement.
SymphonyAI Launches Industrial Large Language Model (LLM) for Smart Manufacturing SymphonyAI has unveiled one of the world's first industrial Large Language Models (LLM), designed to accelerate large-scale industrial transformation. Trained on a massive dataset comprising 3 trillion data points, this LLM leverages predictive and generative AI to enhance operational efficiency, productivity, and SymphonyAI Launches Industrial Large Language Model (LLM) for Smart Manufacturing decision-making in the industrial sector. It offers context-aware data and actionable insights to operators, precision and efficiency. The new version includes a cutting enabling them to make decisions up to 90% faster than mount and guide fence for enhanced versatility and safety. existing systems. Hosted on Microsoft Azure, this LLM Ergonomic improvements reduce vibrations, ensuring a connects and contextualizes manufacturing information at smoother operation and increased durability. The tool offers various levels and supports real-time data analysis, making various cutter mounts, including a 37.5-degree angle option it a valuable tool for intelligent manufacturing. for chamfering tubes. It excels in deburring, rounding, chamfering, and preparing parts for coatings or welding. A TRUMPF Upgrades TruTool TKA 1500 Deburring stainless steel guide fence aids in processing long, straight Tool for Sheet Metal Edges sheet metal and directs chips downward for added safety. TRUMPF introduces an upgraded TruTool TKA 1500 edge Overall, the TKA 1500 delivers improved performance milling tool designed for creating sheet metal edges with and ease of use.
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Advertiser Index Actek Manufacturing and Engineering Inc. — www.actekmfg.com .............................................................35 Advent Tool & Manufacturing Inc. — www.adventtoolusa.com .................................................................... 17 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ............................................................ 7 Behringer Saws, Inc. — www.behringersaws.com ........................................................................................... 13 Betenbender Manufacturing, Inc — www.betenbender.com ........................................................................25 Burr King Mfg Co. — www.burrking.com .............................................................................................................3
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