Industrial Machinery Digest - March 2020 by Industrial Machinery Digest

» Harnessing the Home Field Advantage To Grow Future Manufacturing Talent » Bringing Flexibility to 100% Inspection of Precision Turned Parts » How to Improve Warehouse Efficiency

Manufacturing Showcase: Help Lightning/Cincinnati, Inc. IndustrialMachineryDigest.com

March 2020

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Table of Contents

COLUMNS

10 12

BUSINESS 4.0 Global Forklift Market Analysis, Trends, and Forecasts Shows Growth

TALKING SHOP Amanda McLenithan Senior Engineer, Collaborative Robot Team, FANUC America

FEATURES

MANUFACTURING SHOWCASE

Help Lightning/Cincinnati, Inc.

By Russ Willcutt

WORKFORCE DEVELOPMENT Harnessing the Home Field Advantage To Grow Future Manufacturing Talent

By: Ryan Lizotte, technical service manager, Tregaskiss, and Kevin Pagano, welding automation engineering manager, Miller Electric Mfg. Co LLC

By: Deborah A. Froelich

NEW TECH Bringing Flexibility to 100% Inspection of Precision Turned Parts Whether for short or long production runs, 100% inspection is required for a wide range of parts to meet exacting Six Sigma standards

A Foundation for Success Ash Grove Packaging incorporates Signode stretch hood for greater throughput and product stability

DEPARTMENTS

28 PROCESS

INDUSTRY INSIGHTS

SAFETY & MAINTENANCE From the Gun to the Robot… Supporting Safety in Welding Automation

How to Improve Warehouse Efficiency Ten Tips for Optimizing Warehouse Design and Performance

By: Dave Milner, Vice President of Sales and Marketing, Wildeck

6 8 36 38

EDITORIAL DIRECTIONS INDUSTRY NEWS ON EXHIBIT MODEX 2020

ON EXHIBIT Rapid+TCT

40 PRODUCT SHOWCASE 43 SURPLUS BUYING AND SELLING 49 CLASSIFIEDS 50 ADVERTISER INDEX

ON THE COVER

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4 IMD MARCH 2020

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Editorial Directions SERVING AMERICAN MANUFACTURERS FOR OVER

Each month my mind is blown away while helping to assemble another issue of this magazine. It is both a blessing and a challenge for all of us on the IMD staff to have the opportunity to engage with so many brilliant, leading-edge individuals who are developing the technologies that will shape the future of global manufacturing. This is not an exaggeration; it’s something we enjoy immensely and a responsibility that we take very seriously. But it sometimes drains my capacity for wonderment, so I seek ways to keep myself grounded. One starts with a bell ringing on a creaky old wooden door. I live in a community where there’s an old hardware store. It’s the kind of place where you go in, describe the doohickey you’re looking for, and the owner knows exactly what you’re talking about — and it only costs a buck. Plus there are screws, nuts, and bolts of every size, material, and description, any kind of saw blade you might need, hand tools for your shop, hoses of all types, and repairs available for your air compressor, chainsaw, lathe, jigsaw, you name it. The neighborhood’s retired men gather there, and there is no question you can ask regarding a home repair that won’t be addressed 10 different ways before you leave… an hour later. I see continuity in all this. The hardware shop repairman who balances your table saw shares the same values as a technician using remote assistance to help an onsite machine tool operator test a piece of equipment before it’s returned to service. It’s all about integrity, no matter how it’s delivered.

34 YEARS

William C. Strickland III, Publisher william.strickland@indmacdig.com 800-366-0676 ext. 103 | Fax: 866-826-5918

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Shane Bell, Creative Director sbell@indmacdig.com

SALES

Lisa Hanschu, Sr. Account Executive lisa@indmacdig.com 785-965-9159 | Fax: 785-965-7199

David Marlow, National Sales Director David@indmacdig.com 800-366-0676 ext 200

William C. Strickland III, National Sales 205-903-9178 | fax 866-826-5918

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Susan Strickland, Accounting susan@indmacdig.com 205-542-1098 | Fax: 866-826-5918

Russ Willcutt

Sarah Mayo, Interactive Specialist

Editorial Director, Industrial Machinery Digest

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Industry News Siemens’ MindSphere Continues Industrial IoT Momentum The Industrial Internet of Things (IIoT) has the potential to significantly improve global productivity and growth, with Accenture estimating that this latest wave of digital innovation will accelerate the reinvention of sectors that account for almost two-thirds of world output and add US$14.2 trillion to the global economy by 2030. As companies around the world continue to develop IIoT strategies and implement solutions, they are increasingly partnering with Siemens and choosing MindSphere®, the cloud-based, open Internet of Things (IoT) operating system, as the foundation of their IIoT programs. Recently, Siemens was among the select companies that Forrester invited to participate in The Forrester Wave™: Industrial IoT Software Platforms, Q4 2019 evaluation. In this evaluation, Siemens’ MindSphere was cited as a Leader in Industrial IoT Software Platforms. Over the past year, MindSphere significantly grew its partner program, and announced major new customer wins and Siemens’ expansion of the Mendix platform to include cloud and app services for digital engineering and IoT powered by MindSphere, which is at the heart of its powerful Xcelerator portfolio. MindSphere helps companies understand data by quickly and securely connecting products, plants, systems and machines to the digital world.

GF Machining Solutions Announces New Director of Expanded Sales Department As part of the company’s recent sales and marketing realignment efforts, GF Machining Solutions has announced that Peter Eigenmann, former head of sales for the Southeast region, has been promoted to the Peter Eigenmann position of director of sales and marketing. Peter Eigenmann’s promotion and the organizational changes he has instituted to further improve the company’s customer service and communication supports GF Machining Solutions’ ongoing commitment to quality, innovation and long-term growth in market region North and Central America. Bringing with him extensive experience in machine tools, the mold and die industry and industrial manufacturing operations, Peter Eigenmann joined GF Machining Solutions in April 2013 as the head of project management in Schorndorf, Germany, before serving as the head of sales for the Southeast region. Peter Eigenmann received his undergraduate education in mechanical engineering at the Swiss

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8 IMD MARCH 2020

Institute of Technology in Uzwil, Switzerland, and his master’s certificate in project management from Duquesne University in Pittsburgh.

Visitor Housing for IMTS 2020 is OPEN! Visitor Housing for IMTS 2020, this year’s leading industrial manufacturing event, is now open. Manufacturing professionals across the world will gather at Chicago’s McCormick Place, Sept. 14-19, 2020, seeking to explore the latest in manufacturing technologies and innovative trends. For favorable room rates and locations, IMTS, in cooperation with Connections Housing, contracts the lowest room rates during the event, guarantees your room, and offers free shuttle service from most hotels to and from McCormick Place every day of the show. Beware of false and fraudulent housing claims. The official IMTS housing provider is Connections Housing. “Housing pirates” or “housing bandits,” are companies that phone, fax, or email the IMTS audience, claiming to offer good deals on hotel rooms. They may falsely claim to be affiliated with IMTS. You will not be contacted directly by Connections Housing unless there is a question about your existing reservation.

Ipsen Customer Service Provides Free Furnace Evaluations Ipsen is committed to keeping its products running at peak performance for decades. With more than 10,000 furnaces installed worldwide, Ipsen maintains a strong focus on customer service and aftermarket support. To better serve customers, Ipsen offers free evaluations of any brand of vacuum heat-treating system in the United States. During this comprehensive inspection, an Ipsen Customer Service team member will check all major components of the furnace. The process typically takes under an hour, and Ipsen will provide a written health report with a suggested 18-month maintenance plan. In addition to the free evaluations, Ipsen’s aftermarket services include replacement parts, hot zones, controls and instrumentation upgrades, mechanical retrofits and furnace refurbishments. With a global team of more than 120 field service technicians, Ipsen offers quick and easy access to troubleshooting and repairs, preventative maintenance, instrument calibrations and temperature uniformity surveys.

RobotWorx Announces Offline Robot Programming Through OCTOPUZ Inc. Partnership RobotWorx, an Ohio based company which focuses on quality industrial robotic solutions and customized integration has announced a strategic partnership with OCTOPUZ Inc. The new collaboration will allow RobotWorx to expand its service offerings into offline robot programming with a leading software creator. While traditional robotic programming requires downtime and manual manipulation of a teach pendant, OCTOPUZ provides a better solution. OCTOPUZ enables path-sensitive, complex robot applications to be programmed without disruption to the manufacturing process. Users create detailed virtual simulations of their real-world robot cells, complete with machinery and manufacturing components, in minutes. Within this virtual cell, OCTOPUZ uses built-in machine logic to automatically identify the

IMD – The Industry’s Most Extensive Industrial Publication

optimal toolpath trajectory and program the required code for a multitude of industrial tasks. The code is then accurately converted to the robot brand’s unique language for use in the real world. OCTOPUZ removes the traditional limitations of robot automation by enabling robot programming to be completed virtually, on a computer, while the robots are still online and working for you.

Fives Intralogistics unveils new North American Headquarters and Innovation Center Fives Intralogistics opened its new North American headquarters in Louisville, KY, as the company expands its automated material handling solution operations and services. The facility expands the shop space to 240,000 sq. ft., and incorporates 25,000 sq.ft. of administrative/office space. It also includes a new digital simulation/ emulation lab and a unique Innovation Center with four test loops for proving out automated conveying solutions. This expansion exemplifies Fives’ growing presence in North America aimed at increasing the company’s reach and providing proximity to customers and markets served. The event also marked the launch of the new Fives brand signature: “Industry Can Do It.”

Exact Metrology Set to Open New Center in Moline, Illinois Exact Metrology, a comprehensive metrology services provider, will be adding a new facility. With existing facilities in Brookfield, Wisconsin, Cincinnati, Ohio and an upcoming one in Texas, the

company will have a center in Moline, Illinois. The new location will open on March 1, 2020 and will be located at 4715th Street A. The need for a new space arose from the increasing number of clients in the area. This location will serve as a training, support, contract measurement and sales center. Training will be provided on software packages such as: PolyWorks®, Geomagic and PC-DMIS. The Polyworks® software suite maximizes productivity, quality, and profit, while integrating 3D measurement technologies into an industrial manufacturing process. Geomagic is a leading provider of 3D software that creates digital models of physical objects for industries like aerospace, archeology, medical, dental, tooling and foundry.

MC Machinery Welcomes Shannon Morris MC Machinery is pleased to welcome Shannon Morris as a Regional Sales Representative for North / Central Texas and a portion of East Texas. Shannon will utilize her extensive industry knowledge to support local customers and grow MC Machinery product sales. Having 28 years of outside sales experience, Morris has acquired a comprehensive background in sales and Shannon Morris account management. Her most recent position was with an industrial gas and welding supplies distributor as an outside sales representative in the Dallas-Fort Worth Metroplex / Oklahoma Territory.

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IMD 9

Business 4.0

Global Forklift Market Analysis, Trends, and Forecasts Shows Growth

orklift market worldwide is projected to grow by $3.9 billion, driven by a compounded growth of 2.6 percent. Diesel, one of the segments analyzed and sized in this study, displays the potential to grow at over 2.4 percent. The shifting dynamics supporting this growth makes it critical for businesses in this space to keep abreast of the changing pulse of the market. Poised to reach over $13 billion by the year 2025, Diesel will bring in healthy gains adding significant momentum to global growth. Representing the developed world, the United States will maintain a 2.2 percent growth momentum. Within Europe, which continues to remain an important element in the world economy, Germany will add over $167.8 million to the region's size and clout in the next 5 to 6 years. Over $102.8 million worth of projected demand in the region will come from the rest of Europe markets. In Japan, Diesel will reach a market size of $839.3 million by the close of the analysis

10 IMD MARCH 2020

period. As the world's second-largest economy and the new game-changer in global markets, China exhibits the potential to grow at 3.8 percent over the next couple of years and add approximately $933.4 million in terms of addressable opportunity for the picking by aspiring businesses and their astute leaders. Competitors identified in this market include among others: » Anhui Heli Co., Ltd. » CLARK Material Handling International (CMHI) » Combilift Material Handling Solutions » Crown Equipment Corporation » Godrej Material Handling » HANGCHA GROUP CO., LTD » Hyster-Yale Materials Handling, Inc. » Jungheinrich AG » KION Group AG » Komatsu Ltd. » Lonking Holdings Limited » Mitsubishi Logisnext Co., Ltd. » Toyota Industries Corporation

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Talking Shop Just from an ergonomic standpoint alone, cobots are a real asset to anyone working long hours on the production floor. FEATURING:

TALKING SHOP WITH: Amanda McLenithan — Senior Engineer, Collaborative Robot Team, FANUC America I understand there are different types of cobots. What are the general categories? There are four types of collaborative robot operation, beginning with Power and Force Limiting cobots, which are probably what most people are thinking of when they hear the term collaborative robots. They are designed specifically to be able to sense contact with human workers and cease operation, eliminating the need for safety barriers. They are best suited for smaller applications. For the other three types of collaborative operation, any industrial robot can be integrated with safety devices to be able to become “collaborative” Safety Rated Monitored Stop cobots, which detect when a person has entered a designated area and stops operating until the person leaves that shared workspace, which eliminates the need to have to restart the robot with the push of a button. Once the person leaves, the robot can continue automatically with its task. These are generally used when there isn’t as much interaction between people and the cobot. Speed and Separation cobots, also sometimes referred to as “fenceless,” work well when there is not much interaction with a person, but a person needs easy access to the robot. Safety laser area scanners are commonly used to set up zones near the robot’s workspace so that when a person starts to approach the robot, its movement is slowed down, and it stops altogether once that person gets within reach of the robot’s workspace. As soon as the operator moves out of the robot’s workspace, the robot can resume what it was doing automatically. The final category is known as Hand Guiding cobots, which is where a safety rated device is attached to the end of the robot arm and allows someone to manually guide or move the robot around. This type is often used to help program new paths and positions quickly and easily in just that way — by hand. This type is ideal for mobile applications, moving the cobot between stations and training it to accomplish different tasks, and where the robot needs to frequently be reprogrammed for a new job.

12 IMD MARCH 2020

What were some of the biggest challenges that had to be overcome when cobots as we now know them were first introduced into the industrial environment? As can be expected, we needed to help people overcome the notion that cobots were going to replace their jobs, when they were actually there to function as an assistant in tasks that a person either wouldn’t want to do, like picking parts all day, or would find physically difficult, like lifting heavy objects. A cobot could lift a large car door during assembly, for instance, and hold it in place while a worker made the delicate electrical connections that a cobot couldn’t accomplish. Just from an ergonomic standpoint alone, cobots are a real asset to anyone working long hours on the production floor. Another challenge involved risk assessment, during which the determination is made as to whether a cobot would be suitable for a particular workspace or application. While it’s a definite space-saving benefit of a cobot to be able to eliminate the safety enclosure, you have to remember there are many other moving parts within that work area — there’s a lot more going on in there than just the cobot’s activities. So there are a lot of variables to take into consideration. We had to rethink things like exposure to pneumatic mechanical grippers, and how to keep people safe working near them, so there were a whole host of issues to consider. Nothing can ever be taken for granted in the manufacturing environment.

At the same time, what are the primary benefits that have been realized over the years? Again, the space savings gained by eliminating the safety enclosure really streamlines the workspace, and the flexibility you gain by being able to move a cobot from station to station was a huge asset that people immediately recognized and appreciated. In fact, I think one of the capabilities we hadn’t quite envisioned at the beginning of all this that has turned out to be a huge value-add is how well suited cobots are for high-mix/low volume applications. If you take a look at our new CRX Series, you’ll notice that we’ve paid a lot of attention to things like ease of installation as well as the simplification of teaching it to perform new tasks and functions. That allows users to quickly move from one job or one part to another without having to invest too much time or effort into setting up for whatever needs to be done next. Plus the CRX cobots are lightweight and easy to handle, making them ideal for mobile applications. And another thing we’ve done is designed them to support a new tablet teach pendant as the HMI between the operator and the cobot, which is a much more familiar means of digital communication for most people. And as we see advances in AI, making cobots and other robotic and automatic systems more intuitive, the interface between operator and machine is becoming more fluid and productive, really underscoring the collaborative nature of this technology. Modex 8in x 4.75in Ad Amanda.pdf

13/02/2020

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IMD 13

Safety & Maintenance

From the Gun to the Robot… Supporting Safety in Welding Automation By: Ryan Lizotte, technical service manager, Tregaskiss, and Kevin Pagano, welding automation engineering manager, Miller Electric Mfg. Co LLC

obotic welding systems continue to gain in popularity due to their ability to increase productivity, improve quality and decrease costs in the right application. But they also offer a way to address a shortage of skilled labor for manual operations. Welding automation provide companies with a means of staying competitive in a demanding marketplace, while using their existing and potential workforce to oversee the weld cell.

14 IMD MARCH 2020

With more and more robotic welding systems being implemented — the Robotics Industries Association (RIA) cited that 20 percent of all industrial applications had robotic welding cells as of 2017 — comes the need for increased attention to safety. From the robotic welding gun and peripherals to the robot itself, following safety best practices is essential.

IMD – The Industry’s Most Extensive Industrial Publication

Robotic Welding Safety Hazards and Resources Statistically, welding automation is safer than manual or semi-automatic welding. However, operators overseeing the robotic welding cell must still remain vigilant. This is particularly true when performing nonstandard operations; these include programming, maintenance and any other tasks that involve direct human interaction with the robot. Conducting a thorough welding risk assessment helps identify potential safety hazards associated with a specific robotic welding system (whether it is a pre-engineered or custom cell) and is a critical first step in establishing a safer welding environment. This assessment provides a baseline for implementing solutions for identified risks and establishing appropriate welding safety training. In addition, it helps companies maintain compliance with safety standards, which most importantly protects employees but also protects the bottom line. Noncompliance and/or safety violations that can lead to injury become can be costly in terms of fines and workers’ compensation. Companies can obtain welding safety resources through the American Welding Society (AWS), including Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, a free download at aws.org. The National Fire and Protection Association (NFPA) also offers resources. RIA follows American National Standards Institute (ANSI) standards and offers safety seminars and webinars. RIA also provides information on industrial machinery and guarding, as well as guidelines to help companies, including the American

National Standard for Industrial Robots and Robot Systems – Safety Requirements, ANSI/RIA R15.06-2012. The Occupational Safety and Health Administration (OSHA) is another valuable safety resource. Many robotic welding integrators or robotic welding system manufacturers offer training for the safe use of their equipment, including how to test safety functions and at what frequency. They also provide manuals and safety standards for their systems. It is critical to read and follow these thoroughly.

Safe Use of Robotic Welding Guns, Consumables and Reamers Manufacturers of robotic MIG welding guns often integrate design elements into these products to aid in their safe use. These elements are intended to protect operators during routine maintenance and minimize or eliminate the need to enter the weld cell to complete tasks. For example, guns that are compatible with front-loading liners help improve safety in a robotic welding cell. These liners can be installed from outside the weld cell — there is no need to climb over tooling or maneuver around the robot to complete replacement. Operators or maintenance personnel also don’t need to remove electrical connections to replace components during the process. An insulating disc is another important safety feature in select guns. It helps protect operators from the welding current during maintenance and protects the robot from the current, limiting potential damage.

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IMD 15

In addition to integrated safety features, there are some key best practices for working with robotic welding guns, consumables and reamers (or nozzle cleaning stations). First and foremost, always de-energize the robotic welding system when installing a robotic MIG gun or consumables, and follow all lockout/tagout procedures. When possible, it’s ideal to have a window or opening that allows consumables to be changed or inspected from outside the weld cell. If this isn’t feasible, programming the robot to stop near the weld cell door simplifies consumable changeover and eliminates the need for the operator to enter the cell, maneuver around tooling or climb on anything to complete the job. The appropriate personal protective equipment (PPE) is also important when changing over consumables or the welding wire. The nozzle and contact tip may be hot, and there is the risk of the welding wire puncturing the operator. Leather or other thick work gloves are a must, and safety glasses should be worn at all times. Always use the proper tool to change over the nozzle and contact tip. A pair of welpers is recommended. When performing maintenance on a reamer, begin by resetting the equipment to a home state, de-energizing it and following lockout/tagout procedures. Be certain there is no air or electricity supplied to the reamer. When changing over cutter blades, always wear gloves and use two wrenches to remove and install them. Reset the reamer to a home state when finished. This is an important last step, as the reamer will automatically complete a cycle as soon as it receives a start signal and is reenergized.

Navigating the Robotic Welding Cell Safely Welding operators and maintenance personnel should familiarize themselves with the emergency stops on a robotic welding system as a first safety step. The number and location of these stops varies by system. For example, welding cells typically have an operator station emergency stop that ceases all robot functions and turns off the robot servo power, along with an emergency stop on the teach pendant. Operators should test these emergency stops periodically, although testing too frequently is stressful on the mechanics of the robotic welding system. Understanding brake release procedures is also critical. RIA sets standard requirements for these; however, every robotic welding system is different, and the location of the override buttons may vary. As when interacting with a robotic MIG welding gun, consumables or reamer, always follow proper lockout/tagout procedures before entering the robotic welding cell. Many systems have multiple lockout/tagout locations that are indicated by stickers. Some pre-engineered welding cells feature sliding programming access doors with magnetic keys that indicate that they are fully open and ready to be locked out prior to maintenance, helping to prevent pinch points or a trap hazard. A built-in awareness barrier in pre-engineered cells is another means of aiding operator safety. This hooped barrier inside the weld cell covers the sweep area of the indexing table. Its purpose is to protect the operator from pinch points during teaching operations by separating the him or her from the space between the robot and the wall of the weld cell.

16 IMD MARCH 2020

A built-in awareness barrier in pre-engineered cells is another means of aiding operator safety. This hooped (yellow) barrier inside the weld cell covers the sweep area of the indexing table.

For robotic systems that are not enclosed, guards around the cell are necessary. These can take the form of physical barriers, like perimeter fencing or light curtains and/or electronic guarding such as area scanners that stop the robot when an operator is present in a specific area of the system. Lastly, robotic integrators and robotic welding system manufacturers provide risk assessment documentation, typically in the operator’s manual. It is important to review this assessment thoroughly and train employees on the proper techniques to mitigate any identified risks. For example, programming the robot introduces mechanical hazards such as the potential for pinching or impact, which can be addressed by standing a safe distance outside of the weld cell or by using a slower teach speed if offered on the teach pendant.

Creating a Culture of Safety Safety in welding automation should be top of mind among operators, management and maintenance personnel. Ongoing training needs to be a priority, whether it is conducted through company programs or seminars offered by outside resources. The goal is to ensure that everyone involved with the robotic welding system is playing an active role in employing best practices. When they are followed properly, the result is a safer work environment and a stronger bottom line.

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Manufacturing Showcase

Help Lightning/ Cincinnati, Inc.

By Russ Willcutt

very member of the team at a manufacturing facility plays a crucial and indispensable role in the operation’s overall success, but no one more so than those responsible for keeping the machine tools not only up and running, but doing so at maximum capacity. Downtime must be avoided at all costs, and should it occur, it must be remedied ASAP. But even the most ironclad of service contracts generally require site visits by a technician, sometimes requiring travel, and other related delays. Meanwhile, frustration builds at the plant as questions go unanswered and production backs up. Wouldn’t it be great if that plant service manager had an OEM tech expert in his or her pocket at all times to walk them through sticky situations immediately? Help Lightning, of Birmingham, Alabama, markets a patented technology known as “Remote Expertise” that allows just that type of interaction between those who service, operate, and maintain various equipment on the front lines and OEM experts who can provide immediate answers to questions via smart devices in an interactive manner; meaning hands appear onscreen manipulating the parts in question, circles and arrows can be drawn illustrating points being made in the conversation, and the proper

18 IMD MARCH 2020

nomenclature for what’s being discussed can be clarified visually, avoiding unnecessary confusion. Gary York, CEO, says the technology was developed by a neurosurgeon at the University of Alabama at Birmingham’s (UAB) Medical Center and was initially used in maintaining medical and other complex equipment. “We launched the technology in 2016, and we refer to what we’re providing as ‘Remote Expertise,’” he says. “It brings the OEM’s technical professional and the manufacturer’s service personnel in direct contact immediately using the smartphones and tablets most of

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us are already carrying around with us everywhere anyway.” As can be imagined, the potential applications are endless, so the company has been prudent in identifying and learning about prime new markets as it has grown and moved forward. Its success in complex equipment applications — resulting in some 50,000 users around the world — brought it to the attention of Greg Wilson, director of service at Cincinnati Inc., who encountered York and his partners at a trade show held in Amelia Island, Florida. “I immediately realized how valuable the technology could be to us as a machine tool OEM, so we started a conversation that led to us inviting them to share our booth at Fabtech two years ago. They were astounded by the scope of a show that completely filled McCormick Place in Chicago. They’ve joined us twice more since.” Demonstrations went well, so manufacturing became the next logical target market for Help Lightning to concentrate on. Cincinnati began offering the technology with all its machine tools at around the same time, offering different options during service package negotiations at the point of sale. Wilson says that the experience has been positive, and that benefits continue to be revealed. “For instance, there is a certain category of customer who is of a size where they might not need service assistance but once or twice a year, so we have an option that is ideal for their situation,” he says. “And it’s also helped eliminate the ‘judgment call’ factor when running tests after a repair since the OEM tech might not approve the same results that were found on the floor.” Wilson goes on to say that customer input is invaluable and has led Cincinnati to develop a survey that is automatically generated to both the OEM and the end user after each remote expertise session, allowing the company to gather metrics both for its own internal use and to share with Help Lightning as well, leading to modifications such as product documentation that can be pulled up during help conversations. York recalls a recent visit made by the CEO of a Fortune 100 company that requested a demonstration of the Help Lightning technology. Impressed, she admitted that on many of the service calls her technicians made to assist their customers, they didn’t actually need to be there, physically. “And that’s really at the very center of what we’re addressing,” he says. “Finding the most efficient way of working faster, smarter, and with enhanced teamwork via new technologies.” To learn more please visit www.helplightning.com and www.e-ci.com. INDUSTRIAL MACHINERY DIGEST.COM

IMD 19

Workforce Development

Allied Machine & Engineering celebrates its 75th anniversary with an open house for the public

Harnessing the Home Field Advantage To Grow Future Manufacturing Talent By: Deborah A. Froelich

here’s a lot of chatter in the manufacturing industry centered on skilled trade workforce recruitment and development. Two factors amplify the struggle to find (and keep) great employees in recent years. First, a large portion of manufacturing talent will be eligible to retire by 2020 according to the Bureau of Labor Statistics (BLS). The second factor is the new and next generations’ lack of interest in manufacturing careers. So how can we reignite a passion for manufacturing careers … in both the new and next generations?

The Home Field Advantage Allied Machine & Engineering is sparking curiosity in the classroom and re-shaping community views about worklife on the plant floor. They cultivate talent from home field via two avenues and both

20 IMD MARCH 2020

paths lead students to a high-tech, high-wage manufacturing career, right in their own community.

Route #1: Strength Training and Inspiration in the Classroom According to sources, the skills gap was caused partly by the lack of STEM-educated students in America. Not enough students are prepared to join the high-tech world of manufacturing. With this in mind, Allied Machine started reaching out to classrooms to get students excited about science, technology, engineering, and math (STEM). Steve Stokey, Allied Machine’s executive vice president, began work with community leaders, educators, and business owners county-wide to integrate more hands-on STEM courses in local

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classrooms. A curriculum model created by a nation-wide non-profit called Project Lead the Way (PLTW) helped provide the structure and support needed to start. PLTW curriculum introduces the fundamentals of STEM to kindergarten through fifth-grade classes. Sixth through eighth-graders learn about design and modeling, automation and robotics, and the magic of electrons. At the high school level, students choose from pre-engineering, biomedical, and computer science strands. Mr. Stokey calls this curriculum structure strength training for young minds. “We needed a way to develop engineers and technicians with the complete spectrum of skills, including good work ethic, integrity and the aptitude for continuous learning,” says Mr. Stokey. An annual STEM project competition boasts county-wide participation from elementary students through high school seniors. Engineers from Allied Machine and other local businesses volunteer as judges for this event, and participation grows exponentially every year. In fact,

in 2018 over 300 students competed for accolades in STEM. Another vehicle Allied uses focuses on encouraging young women to consider pursuing a degree in engineering. According to BLS, although women make up 47% of the U.S. labor force, only about 14% of engineers are women. Allied Machine realized this is a great opportunity to grow the talent pool for manufacturers. Two Allied engineers, Mary Jo Hanlon and Jamie Rosenberger have over 38 years of manufacturing and engineering experience collectively. Since they enjoy Tuscarawas county seniors Diana and Madi win the PLTW inspiring young women to get excited about Showcase trophy for their division. engineering and technical careers, they volunteer annually to speak at the Women in Engineering event held at Kent State University Tuscarawas campus. Allied Machine also builds incredible partnerships with local technical schools like Buckeye Career Center (BCC). In fact, Allied Machine humbly accepted BCC’s 2017 Spotlight Award for their support and contributions to scholarships for area students. They also coordinated with BCC to arrange a New Hire Signing Day event, where they honored four exceptional precision machining students and offered them full-time positions upon graduation. The event was designed to celebrate the students’ achievements in academia just as exceptional athletes are celebrated on signing day.

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IMD 21

Parents, business owners, and community leaders pack in to see STEM in action at the annual Tuscarawas PLTW Showcase.

Route #2: Create great curb appeal At times, members of the community can inadvertently discourage interest in skilled-labor careers by sharing negative stereotypes of manufacturing work life. After all, the plant floor they knew was dark, dirty and dangerous. To this day, a lot of folks have never seen a modern, high-tech production facility. With this in mind, Allied Machine peaks interest and reframes thinking by creating great curb appeal and opening its doors to the public. Groups from the area visit throughout the year to see modern manufacturing in action. Over the last year, Allied has given facility tours to students, educators, career counselors, and many others. Each year Allied welcomes participants of the Tuscarawas County Dale Lauren Foland Manufacturing Camp and demonstrates the lean manufacturing process. They’ve also hosted tours for Kent State University engineering students in automated manufacturing and process materials courses. Instructors from the Buckeye Career Center spent their 2018 Teacher In-Service Day touring the plant floor and gathering input for their curriculum planning. Allied Machine realizes the industry can’t rest on their laurels in the current environment. Fortunately, they can build bridges with children and community leaders, create wonder and excitement about manufacturing, and cultivate strong manufacturing talent in their own back yards.

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Allied Machine & Engineering honors precision machining graduates with job offers and a “Signing Day” event.

Allied engineers volunteer alongside other local engineers to judge K – 12-grade students’ STEM projects at the annual Project Lead the Way Showcase event.

ABOUT ALLIED MACHINE & ENGINEERING CORP.: Allied Machine & Engineering Corp is a leading manufacturer of holemaking and finishing tooling systems. Allied devotes its advanced engineering and manufacturing capabilities to create the widest selection of value-added tooling available to metal-cutting industries around the world. Our tooling solutions deliver the lowest cost per hole in a wide range of drilling, boring, reaming, threading, and burnishing applications. Located in Dover, Ohio, Allied’s precision holemaking technologies provide end-users worldwide with the highest level of drill performance. Precision engineering and expert application support make Allied the first and best choice for solving complex metal-cutting challenges. Buckeye Career Center instructors tour Allied’s shop floor during Teacher in Service Day.

For more information, visit www.alliedmachine.com

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IMD 23

New Technology

Bringing Flexibility to 100% Inspection of Precision Turned Parts Whether for short or long production runs, 100% inspection is required for a wide range of parts to meet exacting Six Sigma standards

hen contract machine shops create turned metal parts for the automotive, aerospace, medical and electronics industries, the parts must be increasingly precise to meet the specifications and tolerances required for today’s automated assembly processes. As a result, contract machine shops are increasingly implementing 100% inspection and sorting procedures to achieve near-zero defects, commensurate with Six Sigma standards. However, due to the nature of contract work there can be a wide variety of part types and sizes to inspect, in production

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runs large and small. The challenge is that traditional automated 100% inspection and sorting equipment is typically custom-built for specific parts, and not easily adaptable for others. Manually loaded inspection equipment is more flexible, but can be slow, expensive, and opens the door to human error. Given the increasing demands, machine shops are seeking more flexible alternatives that can be used to run a variety of parts, while allowing for quick changeover as needed. With this type of equipment, a variety of small turned,

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screw-machined, molded or stamped parts up to 4.5 inches long is placed on a rotating glass surface, either manually or using a vibratory bowl feeder. The parts are then conveyed to the inspection area where digital cameras paired with a high-speed LED strobed lamp generate high quality, blur-free images of the moving parts. Software is then used to compare the part against the specifications in a sophisticated and precise gaging process before they are sorted into “pass” and “fail” bins. “Increasing sigma level quality is becoming a requirement and is a driving factor for 100% inspection in today’s machine shops,” says Stephen Kaspari, Vice President at Warren Screw Products Inc, a Warren, Michigan based manufacturer of close-tolerance turned, broach, machined and assembled metal components for industries such as automotive, appliance, commercial, heavy truck, agriculture, and military. “By switching to 100% inspection with more flexible equipment, we gain the ability to run parts manually for as few as 50 pieces, to automated inspection and sorting of more than a million parts at a time,” adds Kaspari. “Our sigma has increased to meet the tightest tolerances, which has helped us win bids as well.”

Flexible, Accurate 100% Inspection According to Kaspari, Warren Screw Products was seeking a method to achieve flexible, high-speed inspection with accuracy up to 0.0001” and was not satisfied with traditional techniques.

“Because of variations in turning equipment and raw material, some product can be out of tolerance,” says Kaspari. “But with the manual end of the line inspection, you may only reach an 80% level of effectiveness [approximately sigma level 2.5] and will not achieve the goal of ‘zero defects’ to meet automotive industry standards.” Not only that, he adds, but manually checking each part for thread presence or pitch diameter is extremely time-consuming and prone to human error. Although Warren Screw Products was using a mechanical sorting system, achieving tighter tolerances was necessary to get as close to zero defects as possible. To accomplish these goals, however, the equipment utilized for 100% inspection had to be flexible enough to inspect a wide variety of parts. “In total, we run 600 active parts that are all uniquely designed for a customer-specific application, so we need the ability to rapidly and flexibly switch over to inspect other parts and part families,” says Kaspari, who notes that some of the parts are for a new Corvette transmission. “So, we needed the ability to quickly inspect turned parts, which could share 10 common features yet have a different diameter, neck length, or thread size.” Kaspari turned to a 100% inspection system, called the ShadowGage Sorter from Resec Systems LLC, a Bergenfield, NJ based manufacturer of automated 100% inspection sorting systems for small turned parts. The sorter utilizes a rotating glass platen to transport, align,

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measure, and sort the parts. Precision optics and a high-speed LED strobed lamp are used to obtain a gage quality image of the moving parts. The part’s dimensions are extracted from the image in a fraction of a second and displayed on a monitor directly over the image. The monitor shows the actual measurements as well as the tolerances. If all the dimensions are within specified tolerances, the part is ejected from the platen by a precisely timed air pulse, which places it into the PASS bin. The rejects remain on the platen and are mechanically forced into the FAIL bin. Each part’s measurements are stored in a file and can be retrieved by most Statistical Process Control (SPC) programs or Microsoft’s Excel®. With the system, an inspection of all external part dimensions is possible to an accuracy of ±0.0001 inches at a rate of up to 7,200 parts per hour, and the sorter can easily be configured to inspect different parts. “Zero defects are required for the automotive market,” says Kaspari. “So, almost every part we run off our screw machines goes to end-of-line inspection equipment like a Resec Systems unit to inspect for out-of-tolerance pieces.” Kaspari estimates that one machine can perform the inspection of 10 to 15 people doing the same work manually. As a result, the equipment had a quick ROI. “With the sorters, we save tens of thousands of dollars annually in labor alone, so we were able to pay off the machines in less than six months,” says Kaspari. The ShadowGage Sorter is offered in two configurations and Warren Screw Products has one of each operating six days a week, 20 hours a day. Flat platen sorters are for parts that have a “flat end” and are not too long, so they can stand on their head. Tilted platen sorters are used for longer parts or those without a flat head. The parts lie “tilted” on their sides on the platen and the unit adjusts the camera angle to provide an accurate measurement. With either system, the measurements performed on each part can be saved as an inspection program for the part and be easily recalled at any time. “We probably have 30 different parts that we run with O-rings on them, and we have to know the O-ring is correctly installed, in the

26 IMD MARCH 2020

correct location, with only one installed on each part,” says Kaspari. “For the parts with O-rings, we have had a very high level of success using the equipment to get to zero defects for our customers.” The ShadowGage sorters can be loaded manually or by using an automated bulk feed system such as vibratory feeder or conveyor, to load parts onto the platen. In manual mode, parts are placed on the transport by hand and the sorter does the rest. For further flexibility, the software is used to create and edit inspection programs, as well as set operational parameters and calibrate equipment. A screen displays the part’s image with the overlaid measurements, and inspection programs are created directly over the interactive image. Software tools are also provided to perform various types of measurements, which are typically applied to determine part diameters and lengths, chamfer measurements, corner radius, angle measurements, circles and arcs, and threads. The tools can be clicked and dragged anywhere over the outline of the part. Measurements are displayed on the screen in a familiar drawing format. After mastering simple programming procedures, it typically takes about 30 seconds to program a single measurement. So, if a

part requires 10 measurements, it will take about 300 seconds, or 5 minutes, to create an inspection program. “Once you learn the basics of the software tools, they are easy to apply to just about anything,” says Kaspari. “Typically, you pick a tool and drag it over a feature like a length or a diameter so it is pretty intuitive and easy to switch from one part to another.” Warren Screw Products typically measures from 7 to 20 turned part features in this way, usually involving lengths, diameters, and thread pitch. Although contract machine shops may be familiar with traditional part inspection methods, the flexibility, speed, and accuracy of 100% inspection of precision turned parts can become a competitive advantage that enhances productivity and profitability. For more info, call 201-384-6960; visit www.resecsystems.com; or write to Resec Systems LLC at 93-A South Railroad Ave, Bergenfield, NJ 07621.

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IMD 27

Process

A Foundation for Success Ash Grove Packaging incorporates Signode stretch hood for greater throughput and product stability

ement has been a critical component of America’s growth for hundreds of years. It is the literal foundation block for most all that surrounds us. For more than 132 of those years, Ash Grove Cement Company has been meeting market demand from its 8 facilities nationwide. The cement plants operating in the Ash Grove system are some of the most efficient and best maintained in the country and have an annual production capacity of nearly 9 million tons of cement. The quality portland and masonry cement produced at these plants are used in the construction of highways, bridges, commercial and industrial complexes, single and multi-family homes, and a myriad of other structures fundamental to America's economic vitality and quality of life. Ash Grove Packaging, a subsidiary of Ash Grove Materials Corporation, has helped bring the company’s products to a broader range of loyal customers. From its early days of supplying cement in simple hand-sewn sacks, the company has grown into an organization that today offers a full array of products designed for commercial, residential and industrial use. As a premier packager of cement products in the United States, Ash Grove Packaging puts as much care into the manufacturing of its products as it does to ensure it arrives to customers in optimal condition. In its largest facility in Utah, a new pallet wrapping system offered Ash Grove Packaging the chance to not only meet customer demand but further improve warehouse efficiencies.

Stable Solution Most all Ash Grove products are packaged in bags and stacked on standard pallet loads. To avoid shifting or tipping during transport, pallets are typically stretch wrapped. However, as cement bags are packaged in paper bags, it’s important for manufacturers to place a top sheet of stretch film on the load to avoid tears from pallets being stacked or moisture seeping from the top and destroying the product. Initially, Ash Grove Packaging incorporated two rotary arm stretch wrappers to do that job. The process involved two men- one driving the forklift while the other tied the film to the load and held in place for the first revolution of film. A separate top sheet was also applied. In January of 2014, Ash Grove Packaging, looking for ways to improve and optimize its process, turned to its trusted partner

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Signode. After reviewing the company’s challenges and operations, Signode suggested its Power Flex T1 stretch hood machine. It was the perfect solution as it provides 5-sided protection for outdoor storage and ensures greater load stability. It also removes the need for the top sheet because the stretch hood film creates a tight bag over the load. Furthermore, the Power Flex T1 requires only one layer of the film as opposed to applying multiple layers of film with stretch wrapping. The single-layer offers greater product visibility and stability. “Before when products would shift it would stretch the film and loosen to load,” says Engel Islas, Plant Manager, Ash Grove Packaging. “The Signode system gives us a clean wrap you can see through with the added advantage that it’s a much more stable load.” Retailers have also taken notice. With pallets stacked high on the shelves, Ash Grove Packaging reports its customers have been pleased that the loads are arriving more secure and in turn, provide a safer environment for their staff and customers.

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Small Package, Big Results Even though pallet stability was crucial, Ash Grove Packaging still had high demand and a packed facility. Size and speed were also big factors to consider when switching to the Signode. Signode had just the solution in the Power Flex T1 because it enabled Ash Grove Packaging to place the machine in an area where most other solutions could not be placed. With the film carriage on casters, workers can simply unlock the carriage like a door and the forklift driver can go in without needing extra space. It also requires only one person to operate as opposed to the two necessaries with their stretch wrappers. That cut costs on labor as well as limiting the potential for employee injury. With regards to speed, Ash Grove Packaging was previously wrapping 22 loads per hour whereas the Signode Power Flex T1 wraps 30 loads per hour. While the Power Flex T1 can wrap up 120+ loads per hour, it is conditional on application and production. At Ash Grove Packaging, the palletizers can only handle roughly 25 bags per minute. “We are now utilizing an area we never have before and doing so with a solution that offers us much more throughput,” says Engel.”

Set Up and Save While the benefits are clear, most manufacturers are reluctant to incorporate new machinery because of the time, energy and costs associated. However, the Signode system proved to be no challenge

for Ash Grove Packaging and the company had the machine running fairly quickly with little effort. “From set up to training, it all went really smooth,” says Engel. “We have had it running for several months now and it’s proved to be a very reliable machine and easy to maintain.” The Power Flex T1 is designed with top-down features. These features enable the safer operation and easier maintenance since the machine can be moved to floor level. Like all Signode stretch hood machines, the Power Flex T1 also comes standard with the company’s patented Unwind System which helps manufacturers optimally protect pallet loads while simultaneously reducing film usage 10-25%. The system gathers the film at the corners and unwinds it as the film placed over the load. This process virtually eliminates thin and fragile film on load corners- a feature that is especially important for loads with sharp edges. Compared to other stretch hood systems, Signode’s Unwind System further keeps film corners roughly 30% thicker. In addition, users can safely incorporate up to 25% lighter film gauges without compromising load integrity. “In our short time with the Signode system we have already seen considerable film savings compared to other methods we have used,” says Engel. “Coupled with the important fact that we have increased throughout and product stability, I would say it has been a great investment thus far.” For more information, visit www.signode.com

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Industry Insight

How to Improve Warehouse Efficiency Ten Tips for Optimizing Warehouse Design and Performance By: Dave Milner, Vice President of Sales and Marketing, Wildeck

arehouses and distribution centers are under an increasing amount of pressure to move more product through their facility faster. While the adage to have “a place for everything and everything in its place” may have once sufficed as a means for achieving warehouse efficiency,

30 IMD MARCH 2020

this practice alone is now insufficient. Companies looking to obtain and maintain a competitive advantage need tools and best practices that save time and money. The following ten suggestions, when strategically implemented, can help improve warehouse efficiency.

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other areas of the facility is decreased. Simple changes like this can dramatically improve warehouse efficiency.

2. Maximize All Available Space For warehouses and distribution centers that are bursting at the seams, a facility renovation or move seems like the obvious solution. However, with ceiling heights in excess of 30-feet tall, most warehouses and distribution centers have not exhausted all the available square footage their facility has to offer. Industrial mezzanines provide a way for companies to fully utilize their existing overhead space, increasing warehouse efficiency and profitability at a fraction of the cost of the alternatives. While the mezzanine’s exact specifications will dictate the amount of installation time needed, most can be erected in a matter of weeks with minimal disruption to a facility’s daily operations.

3. Provide and Maintain the Right Equipment 1. Examine Warehouse Layout Warehouse layout directly impacts the speed with which materials are received, sorted, retrieved and shipped. Companies that understand this correlation create workflows that minimize the amount of unproductive time spent handling materials and equipment, resulting in higher levels of organization and productivity. For example, warehouse efficiency can be increased by placing the product packaging area near the shipping/receiving bay. By doing this, the amount of time spent transporting packages from

When looking for ways to improve warehouse efficiency, it is imperative that companies invest in the right tools and equipment for the job. For instance, vertical reciprocating conveyors (VRCs) and rideable material lifts (RML) offer a safer and more efficient way to move warehouse cargo, especially when compared to a forklift or pallet jack. Companies that make wise investments in tools and equipment find that productivity and safety increase as employees are not forced to find time-consuming and dangerous workarounds. Additionally, warehouse efficiency can be enhanced

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through routine maintenance programs. Pre-shift equipment checks and scheduled recommended maintenance are a great way to catch and resolve potential equipment issues. By implementing this best practice, facilities increase their likelihood of staying fully operational.

4. Automate Automation is a great way to improve warehouse efficiency. Companies that choose to automate quickly see an increase in throughput, productivity and order accuracy while simultaneously achieving a reduction in product damage. Common warehouse processes that can be automated include product sorting, storage, and transportation. While automation is a viable option for new and existing warehouses, careful consideration will need to be given to warehouse design. Specifically, warehouse layouts will need to be designed to accommodate the space requirements of the intended automated equipment. For information on how industrial mezzanines can provide the space needed for automation, read our blogpost: “Four Benefits of a Wildeck Mezzanine.”

5. Eliminate Traffic Traffic congestion is one of the greatest hinderances to warehouse efficiency. With people, equipment and materials all traveling in the same space at the same time, the likelihood of an accident is high. One way to improve warehouse efficiency is to establish clearly defined lanes for each type of traffic (i.e. motorized and pedestrian). To ensure personnel complies with established traffic patterns, companies should consider installing strong physical barriers like steel guard rail. When properly installed, steel guard rail creates a boundary that cannot be easily crossed, enhancing a company’s overall safety and productivity.

6. Train and Train Again A lack of training and/or understanding can substantially undermine warehouse efficiency. Employees that are not properly educated can only operate based on what they think is correct, not what they know. Frequent and repeated training programs can bolster knowledge of best practice, creating environments that are safer and more productive. Companies looking to implement a robust training program should plan short meetings (30-45 minutes) that are dedicated to addressing one topic or process. Information presented this way is more easily digested and implemented, helping companies achieve their warehouse efficiency goals.

32 IMD MARCH 2020

7. Get Employee Feedback As is often the case, two-way communication is the key to success. In their efforts to improve warehouse efficiency, companies should not forget to solicit feedback and input from their employees as they are keenly aware of where the process pitfalls lie. Company initiatives that seek to obtain these insights should be administered frequently so that changes can be gradually and methodically implemented. By fostering a culture that continuously solicits the employee perspective, the likelihood of achieving and sustaining meaningful change is increased, allowing companies to meet or exceed their efficiency goals.

8. Prioritize Safety Since accidents and injuries can substantially limit an employee’s productivity, companies looking to improve warehouse efficiency should closely examine their safety culture. One way that this can be done is through the formation of a safety committee comprised of individuals from across the organization. The diversity of perspectives will ensure that a variety of issues are addressed. Additionally, the employee engagement aspect will give committee members a sense of ownership in resolving issues and will more

evenly distribute the responsibilities. Creating a safer, more efficient warehouse requires everyone’s participation. For help identifying the areas of your facility that could benefit from a safety upgrade, contact Wildeck for a free safety audit.

9. Implement Lean and Continuous Improvement Practices The pressure placed up warehouses and distribution centers to do more with less is not a trend forecasted to leave anytime soon. One best practice that dramatically influences warehouse efficiency is the implementation of lean and continuous improvement practices. Simply put, lean and continuous improvement practices focus on streamlining workflows to save time and money while reducing wasted time and effort. Tangible benefits that companies recognize from implementing these practices include increased productivity and quality and decreased costs and employee turnover rates, all significant drivers of warehouse efficiency.

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10. Measure and Report Performance Key performance indicators (KPIs) are a set of measurements that quantify a company’s effectiveness in reaching their strategic and operational goals. Order lead time, backorder rate, picking accuracy and inventory turnover are common KPIs used to measure warehouse efficiency. The regular measurement and evaluation of KPIs give a company insight into the areas of the warehouse that are performing well and shines a spotlight on processes that need improvement. Once trouble spots have been identified, employee insights can be leveraged to address and resolve the issue.

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or industry. When carefully reviewed and applied, these ten tips can help warehouses and distribution centers achieve their warehouse efficiency goals. At Wildeck, they believe that they have a responsibility to ensure

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that our material handling products contribute to a company’s success. If you would like additional information about the tips and products outlined above, contact Wildeck at (800) 325-6939 or info@wildeck.com.

at www.adbhoistrings.com | 800.423.4425

ABOUT THE AUTHOR Dave Milner is Wildeck’s Vice President of Sales and Marketing. In this role, Milner is responsible for directing all sales and marketing strategies, overseeing the growth of Wildeck’s distribution network and expanding the company’s reach within the material handling marketplace. Milner’s focused results-driven management style, along with his ability to lead a high-performance sales team across multiple channels, positions Wildeck to capitalize on existing marketing opportunities and generate greater product demand. In looking to the future, Milner is excited to maintain the

company’s reputation as the industry’s preferred solutions provider. He

5740 Hunt Road | Valdosta, GA 31606

can be reached at dmilner@wildeck.com. INDUSTRIAL MACHINERY DIGEST.COM ADB Hoist Rings Ad_01 .indd 3

IMD 33 8/13/19 11:31 PM

DYNABRADE’S SELECTION OF AMERICAN MADE DIE GRINDERS NEW ALUMINUM HOUSING TOOLS Dynabrade, Inc. is proud to introduce a new line of Aluminum Housing Air Tools. Newly refined Die Grinders, Disc Sanders and Drills are manufactured to ensure a lightweight tool. Excellent for overhead or extended use. Each tool is manufactured with the rigidity and strength of a housing machined from a single piece of aluminum bar stock. STRAIGHT LINE DIE GRINDERS: Available in 25,000 and 30,000 RPM: These rear exhaust tools are widely used in aerospace manufacturing facilities for deburring and material removal applications. The straight-line design is ideal for applications in confined areas. RIGHT ANGLE DIE GRINDERS: Available in 12,000 and 20,000 RPM: These rear exhaust tools provide greater torque under load when aggressive material removal is necessary. The compact size improves maneuverability and the precision gears provide enhanced durability and performance. PENCIL DIE GRINDER: Utilized in grinding and deburring applications where a high degree of precision is needed. At 100,000 RPM, the tool features low run out for smooth operations. The high RPM creates chatter free cutting and the top-quality bearings provide long tool life. These new Dynabrade Aluminum Housing Air Tools are manufactured in the USA.

STEEL HOUSING DIE GRINDERS Dynabrade’s line of Steel Housing Die Grinders feature high quality steel housings, ideal for heavy-duty applications where durability is required. This line of Die Grinders is available with either .5 hp or .7 hp Air Motors. Each tool features a rubber grip housing to insulate the operator from vibration and cold air transmission. Each tool also comes standard with a 1/4" collet, but can easily be changed to a 3/8" or 1/8" collet with available collet inserts. The tools are available in either 20,000 RPM or 24,000 RPM in front and rear exhaust designs. Standard and extension models are also offered. Rear exhaust models can also accept overhose assemblies for reduced sound levels and/or exhaust redirection. A 20,000 RPM extension model is also available with a 3/8"-24 thread; ideal for use with Cone/Plug Grinding Wheels. These tools are made for heavy-duty applications. Examples of target markets would be Shipyards, Foundries, Steel Fabrication and Welding Operations. Made in the U.S.A.

.4 HP DIE GRINDERS Dynabrade’s line of .4 Hp Die Grinders are ideal for precision grinding, deburring and blending on a wide variety of materials. These air tools, compact and lightweight, are available in RPM ratings from 950 - 30,000 and feature a composite overmold housing, which reduces tool vibration and cold air transmission to the operator. Additionally, each tool includes a muffler, which dramatically reduces sound levels in the workplace. The .4 Hp Die Grinder tools series is available in either straight-line, right angle or 7° offset handle designs. Choose a specific style of Die Grinder for the type of job you are doing. Additionally, the tools are available in geared or gearless models. Geared Die Grinders have higher torque levels while gearless tools offer reduced maintenance and downtime. Front and Rear Exhaust models are also offered. The .4 Hp Die Grinder Series powers optional carbide burrs and mounted points for deburring, grinding, etching, cleaning and more. Additionally, different size collets and collet inserts are also offered. Made in the U.S.A.

DYNABRADE’S SELECTION OF AMERICAN MADE DIE GRINDERS EXTENSION DIE GRINDERS Dynabrade’s line of .4 Hp Extension Die Grinders allow for efficient work within long pipes, castings, and other places where an extended reach is needed. The .4 Horsepower straightline air tools are available in either a front or rear exhaust air motor and run at 25,000 RPM. The new tools are available in two different shaft lengths; 3" Extension Models or 6" Extension Models. These .4 Hp Extension Die Grinders allow the operator to extend into work pieces and reach previously inaccessible areas. Each .4 Hp Extension Die Grinder features a safety-lock lever to prevent accidental start-up of the tool. Also, the tools run as low as 72 dB(A) to further reduce sound in the workplace. The .4 Hp Extension Die Grinder powers optional carbide burrs and mounted points for deburring, grinding, etching, cleaning and more. Made in the U.S.A.

PENCIL GRINDERS Dynabrade’s line of Pencil Grinders is ideal for precision deburring and metal removal on investment castings and other materials. It is also excellent for use on toolings, dies, molds, production parts and much more. The Pencil Grinder features a lightweight, ergonomically designed, vibration-free handle, ideal for reducing operator fatigue. Available in speeds of 65,000, 50,000 and 35,000 RPM, the high-speed air motor is controlled with a patented governor, providing constant speed under load. The efficient air turbine design uses a maximum of only 8 SCFM at 90 PSI, 5 SCFM at idle. The Pencil Grinder has a precision, high tolerance, low run-out collet. Run-out is a true .002 @ 1" from face. An easy change collet insert is available in three sizes; 1/8", 3/32" and 3mm. Additionally, the tool features a guarded collet with tactile warning to keep fingers close to the workpiece and away from the collet and burr. The tool also features a super flexible air hose for maximum agility. The tool is ideal for use on Metal, Plastic, Composites, Precious Metals, Titanium, Fiberglass, Glass, Precious Stones and various Non-Ferrous Metals. Made in the U.S.A.

VARIABLE SPEED PENCIL GRINDER Dynabrade’s Variable Speed Pencil Grinder allows you to easily adjust the speed from 0 – 60,000 RPM to suit a variety of grinding applications. This Pencil Grinder offers precision deburring, finishing and engraving with an easy, adjustable speed flow control. Simply set your speed with the touch of a dial. The tool remains at the desired speed until the operator changes it. The tool features a high quality air-line, an overhose assembly that helps direct air away from the operator, and an Ergonomic Tactile Grip for a non-slip, comfortable operation. The tool also has an easy one-touch push button for easy on/off operation. A convenient Spindle Lock has a “thru-hole” for quick accessory change. No need to struggle with two wrenches. This tool is ideal for use with Turbine Blade Manufacturers, Tool and Die Shops, Machine Shops, Investment Castings, Jewelry, Medical Implants and various Composites Markets. The tool includes a 3mm collet and accepts Carbide Burrs and Mounted Points. Made in the U.S.A. No obligation demonstrations on these and any product in the Dynabrade line are available. Please call 1-800-828-7333 or visit www.dynabrade.com for details.

WE LISTEN. WE OBSERVE. WE OPTIMIZE.

On Exhibit

MODEX 2020 DATES: MARCH 9 – 12, 2020 Location: Atlanta’s Georgia World Congress Center When the largest manufacturing and supply chain expo of 2020, MODEX, opens on March 9 it will include 950 exhibits from leading solution providers and a comprehensive Educational Conference of over 150 sessions focusing on best-in-class solutions for manufacturing and supply chain operations. MODEX 2020 exhibits will represent all segments of the material handling, logistics and transportation industry, from traditional, manual equipment to automated/robotics systems and digital supply chain technologies. » For more information, visit www.modexshow.com

EXHIBITOR HIGHLIGHTS..................................................................................

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Big Ass Fans Continues Innovative Industry Leadership with Powerfoil D The exceptionally engineered Powerfoil D is the first and only direct-drive overhead fan designed for harsh industrial environments. Powerfoil D illustrates the company’s continued commitment to building premium-quality products specifically designed for customer spaces. Powerfoil D delivers strength and performance required for industrial applications, but with virtually silent operation and aesthetic appeal to thrive in any commercial or public setting. The Powerfoil D features diameter options from 8 to 24 feet and includes a 10-year mechanical warranty. » For more information, visit www.bigassfans.com BOOTH: 3819

Douglas Battery™ to Feature Legacy® Battery and Charger Douglas Battery will display a collection of its Legacy® batteries at this year’s MODEX show, including the company’s high performance and low maintenance power solutions. Legacy® batteries deliver excellent conductivity, are corrosion-resistant and include a sleeved positive plate separator to eliminate shorts and potential misalignments. Douglas Battery will also display its charger portfolio. The LegaC2™ modular charger, featuring one of the industry’s most compact and efficient designs, is suitable for a wide range of battery capacities, opening up the possibility of fewer chargers required for a fleet. » For more information, visit www.douglasbattery.com

36 IMD MARCH 2020

IMD – The Industry’s Most Extensive Industrial Publication

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OZ Lifting to Show New Davit Cranes The Winona, Minnesota-based manufacturer is making its debut at the event. The patent-pending Tele-Pro davit crane allows users to leverage the benefits of other lifting technologies in its range, while telescoping the boom in and out under load. The new davit will be the centerpiece in the show’s Fulfillment and Delivery area, where OZ Lifting is hoping to engage visitors seeking solutions for order fulfillment; e-commerce and omni-channel fulfillment; order packing and packaging; third-party logistics; warehousing; distribution; and transportation. However, the breadth and diversity of OZ Lifting’s range will apply the products to a much wider audience. » For more information, visit www.ozlifitingproducts.com BOOTH: 1007

Autonomous Machine Tending in Modular Cell The UR+ ecosystem of products certified for plug-and-play integration with Universal Robots cobots is growing rapidly, now featuring over 200 UR+ products with more than 400 companies in the UR+ developer program. One UR+ partner generating a lot of interest is Vention, with its cloud-based 3D CAD that allows users to easily design, simulate and commission a complete robot cell in as little as three days. Machine tending is one of the most common collaborative robot applications. Despite widespread use, each application requires a somewhat customized robot cell to unlock the full value potential. Vention accelerates the time-to-market with its fully customizable machine tending cells. » For more information, visit www.universal-robots.com

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IMD 37

On Exhibit

Rapid+TCT DATES: APRIL 20 – 23, 2020 Location: Anaheim Convention Center | Anaheim, CA RAPID + TCT is North America's preeminent event for discovery, innovation and networking for additive manufacturing, bringing together the best new ideas from the biggest and most innovative names in the industry. The globally-renowned RAPID + TCT conference brings together over 100 industry experts to speak on the latest processes, applications, materials, and research in additive manufacturing. » For more information, visit www.rapid3Devent.com

EXHIBITOR HIGHLIGHTS.................................................................................. BOOTH: 3713

Metal Additive Manufacturing for Mold Tooling Aerojet Rocketdyne 3DMT uses conformal cooling for their metal injection molding, magnesium thixomolding and plastic injection molding to improve quality, reduce cycle time and enable designs not previously possible. The inserts are additively manufactured on EOS and Concept Laser equipment using M300 steel and then machined finished to tolerance. By printing cores with complex internal cooling, it is possible to greatly improve temperature uniformity, cool locations impossible to reach with traditional machined components and achieve higher heat transfer. » For more information, visit www.3dmt.com BOOTH: 1507

CGTech to Demonstrate VERICUT 9.0 & Composite Application Enhancements CGTech will demonstrate new and enhanced features in VERICUT version 9.0, the latest release of VERICUT CNC machine simulation, verification, and optimization software. The aerospace industry continues to push for lighter, faster, and more cost-effective parts. To support these goals, VERICUT 9.0 features several enhancements designed to increase power and improve efficiency. A new graphics engine provides users with sharper, clearer and more realistic views of machines and the machining process. Any of VERICUT’s major functions, such as AUTO-DIFF, Section, and X-Caliper, can be used in any view which streamlines the verification effort and increases productivity. » For more information, visit www.cgtech.com BOOTH: 3019

Desktop Metal Launches World's First Metal Binder Jetting System for Machine Shops With the Shop System, shop owners can eliminate many of the constraints previously seen with traditional manufacturing methods like CNC machining and tap into new opportunities to reduce their costs and increase revenue. With the addition of this new system, Desktop Metal’s solutions portfolio covers the full metal product lifecycle - from the office-friendly Studio System™ for low volume prototyping, to the Production System™ for mass production, and now with the Shop System, mid-volume runs of complex metal parts on the shop floor. Users can print end-use metal parts that span a variety of industries. » For more information, visit www.desktopmetal.com

38 IMD MARCH 2020

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BOOTH: 200

Markforged Releases the First Generally-Available Solution for 3D Printing Pure Copper Markforged announced the release of pure Copper for the Markforged Metal X system, making it the only reliable, affordable, and safe way to 3D print the widely used material. 3D printing copper parts on demand will drive new manufacturing and supply chain efficiencies for customers – leading to reduced lead times and part costs, as well as eliminating the need for costly inventory. Available today, Markforged provides an easy and fast way to produce geometrically complex copper with high electrical and thermal conductivity. » For more information, visit www.markforged.com BOOTH: 3025

High Precision Building Of 3D Parts Being a complete supplier in additive manufacturing of metal parts DMG MORI offers the LASERTEC 3D hybrid and LASERTEC 3D series for laser deposition welding and LASERTEC SLM series in the field of powder bed machines. The most precise model of the LASERTEC SLM series has the biggest building volume of its class, offering 4.9 x 4.9 x 7.9 in. The LASERTEC 12 SLM achieves its precision with a focus diameter of only 35 µm (0.0014 in). The LASERTEC 12 SLM offers material changes in less than 2 hours by changing the rePLUG powder modules. » For more information, visit us.dmgmori.com

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IMD 39

Product Showcase

PRODUCTSHOWCASE WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

IMD's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

Larger 303SS Air Conveyor Converts Standard Pipe to Convey in Corrosive Environments EXAIR’s new Type 303 Stainless Steel 2-1/2 NPT Threaded Line Vac Air Operated Conveyors convert ordinary pipe into a powerful conveying system for parts, scrap, trim and other bulk materials. They are ideal for food, chemical, pharmaceutical and medical processes or areas likely to be wet and corrosive which require the benefits of 303SS including excellent chemical and corrosion resistance, performance in higher temperatures, long service life and low maintenance. Their larger size makes them perfect for conveying bigger parts and large volumes of material over long distances. The Threaded Line Vac is designed to attach to standard plumbing pipe couplers, making it easy to build a complete system using common pipe and fittings that are readily available. Threaded Line Vac Conveyors eject a small amount of compressed air to produce a vacuum on one end with high output flows on the other. Response is instantaneous and regulating the compressed air pressure provides infinite control of the conveying rate. Applications include scrap trim removal, material conveying, part transfer, fiber tensioning and filling operations. » For more information, visit www.exair.com

Introducing the Grizzly Model G0853 Grizzly’s G0853 is a 14-inch 10 HP 3-phase sliding table saw with digital fence. The G0853 features digital controls for main blade speed, blade tilt, scoring blade alignment, and rip fence adjustment The max width of cut with rip fence: 511⁄4”; max length and width of cut with sliding table: 126" x 126". The G0853 features three main blade speeds—3000, 4000, and 5000 RPM, and 0–45° blade tilt. The versatile table saw accepts 12" and 14" main blades with a 1" arbor. » For more information, visit www.grizzly.com

Jumbo Electric Walk-In Oven From Grieve No. 976 is a 500ºF (~260ºC) electrically-heated jumbo walk-in oven from Grieve, currently used for heating molds at the customer’s facility. Workspace of this unit measures 13’W x 28’D x 7’6”H. 360KW are installed in Incoloy sheathed tubular elements to heat the oven, while 49,000CFM from two 20HP recirculating blowers provide a combination airflow to the workload. This Grieve jumbo walk-in oven features 4-inch thick insulated walls, removable top-mounted heat chamber (shown in the right foreground of the attached photo), aluminized steel interior and exterior, door seals eliminated and doors equipped with drag seals. » For more information, visit www.grievecorp.com

40 IMD MARCH 2020

IMD – The Industry’s Most Extensive Industrial Publication

Siemens Introduces Sinamics V20 Smart Access Web Server Module

The 8.5-inch x 27-inch Vertical Machining Center provides an economical solution for machining small parts. An automatic tool changer and 8-tool magazine make the machining center ideally suited for prototyping and short run shops. Standard features on the #9680185 include linear guide, serve-drives and ball screws on all three axes; safety switches on all doors for improved safety while machining and a central lubricating system to deliver oil to guideways and ball screws. Now observing its 100th anniversary, Palmgren is a C.H. Hanson brand.

Siemens announces the launch of its Sinamics V20 Smart Access web server module, designed to mount directly onto the drive, transforming a mobile device or laptop into a virtual operator panel for drive control. By providing a wi-fi hot spot, the wireless connection on this module facilitates setup, programming, commissioning, production monitoring and maintenance on a variety of machines and production equipment. A simple, embedded graphical user interface (GUI) enables easy use of the Sinamics V20 in every phase of operation. No separate app is required, nor is a written operator manual needed, making operation of this new server module and subsequent drive control highly intuitive and easy-to-learn.

» For information, visit www.palmgren.com

» For more information, visit www.usa.siemens.com/sinamics-v20

New Vertical Machining Center from Palmgren

C-FRAME PRESSES

BEA 16 Spindle Machining Unit With All New Drive And Control Concept The BEA 16 machining unit itself is a precision device from the SUHNER spindle machining unit series that has been designed for grueling continuous use in multiple shift operations. Today, rising production piece numbers and greater workpiece complexity with all-round machining are leading to a renaissance of the so-called special machine. However, today’s special machines are being used no longer as purely single-purpose solutions, but rather for whole part families. These require different machining cycles, feed speeds, feed paths and rotating speeds, and, of course, must allow fast retooling. It is these requirements exactly that the BEA 16 will meet to the full.

• Heavy Gauge Steel Design • Press Bed bolted on, not welded, to prevent distortion. • Large press bed to accommodate a variety of tooling other than just punching. • Pump, motor, valve and reservoir are all easily accessible for maintenance. • Large rectangular tubes used at base of machine to give safe, instant portability.

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IMD 41

New Advance HSS-E a cost-effective new thread former from Walter Walter has introduced the TC410 Advance HSS-E thread former can be used universally for blind and through-hole threads in most materials having a primary application in ISO material groups P, M and N and ISO K and S as a secondary application. Key advantages for using the TC410 Advance thread former are superior performance, reduced torque and longer tool life thanks to new geometry and a post-treatment after the coating process. The post-treatment provides an extremely smooth surface on the tool that reduces friction between the tool and the workpiece.

EWAG LASER LINE ULTRA Simplifies Micro Cutting Tool Production

» For more information, visit www.walter-tools.com

As products grow thinner and lighter to meet the needs of the electronics, medical and micromechanics industries, UNITED GRINDING and EWAG have developed the LASER LINE ULTRA for machining the incredibly precise microtools required for these applications. Specializing in the laser fabrication of cutting tools made of hard and ultrahard materials such as tungsten carbide (WC), polycrystalline diamond (PCD), chemical vapor deposition diamond (CVD-D) and cubic boron nitride (CBN), the LASER LINE ULTRA uses an 8-axis configuration and picosecond lasers to machine complex micro geometries in cutting tools regardless of the material’s hardness and with negligible heat-affected zones. » For more information, visit www.grinding.com

char-lynn hydraulic products low speed high-torque motors… The Char-Lynn

motor range consists of three major types based on the valving used to distribute fluid through the Orbit gear set (geroler or gerotor), Spool Valve, Disc Valve and VIS (Valve-in-Star). A variety of displacement sizes are available in each of the three motor types to provide a wide range of speeds and torques.

steering control units… offer these advantages: • Minimal steering linkage reduces cost, provides design flexibility. • Complete isolation of load forces from the control station. • Continuous, unlimited control action with low output torque. • Wide selection of control circuits and meter sizes. • Works with many kinds of power steering pumps or fluid supply. gear pumps… Eaton Series 26 gear pumps with 13-tooth gears minimizes flow ripple to reduce noise and vibration. Bearing lubrication system uses inlet oil rather than high pressure oil, improving volumetric efficiency and power output. The 13 available displacements and many mounting configurations provide for an easy retrofit. Other series available. 7355 N. Lawndale Ave., PO Box 6, Skokie, IL 60076

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

42 IMD MARCH 2020

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IMD 43

Public Auction - Airway Heights,WA

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Industrial Machinery Digest - March 2020

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Industrial Machinery Digest - March 2020