Industrial Machinery Digest - March 2022 by Industrial Machinery Digest

IndustrialMachineryDigest.com | March 2022

North America’s Manufacturing Resource for Industry Professionals Since 1986

» The Cutting Edge of Aerospace Machining: Ensuring Parts are Precise and Reliable for Critical Applications » 8 Questions for Better Plasma Cut Parts » Recruitment, Retention and Development Remain Critical for Competitiveness » Lost in Logistics No More! Scalable robotic automation helps navigate the way to productivity » 100% Inspection High-Speed Non-Destructive Ultrasonic Scanning Identifies Minute Defects in Specialty Metals and Alloys » 10 Inventory Must Do’s for Small to Medium-Sized Manufacturers

UNWANTED UNWANTEDINVENTORY INVENTORY TAKING UP VALUABLE TAKING UP VALUABLESPACE? SPACE? Radwell.com purchases industrial automation product Radwell.com purchases industrial automation product

Whether you one facility or facilities, ourhave Asset Recovery program is

hether you have one facility or multiple

multiple facilities, our Asset Recovery W hether you have one facility or multiple

an exceptional for your company. facilities, ourresource Asset Recovery program is We offer cash for parts and products you don’t an exceptional resource for your company. We need. In cash many cases, your excess inventory offer for parts selling and products you don’t need. to Radwell gives you your the opportunity of adding dollars In many cases, selling excess inventory to

SELLING TOUS US SELLING TO IS AS EASY EASYAS AS IS AS 1. 1.

Gatheritit Gather

2. 2.

Boxitit Box Radwell.com - 800.884.5500 - sellto@radwell.com Radwell.com - 800.884.5500 - sellto@radwell.com

3. 3.

Arrange Arrangefree free pick pickup up

program is an exceptional resource for your company. We offer cash for parts to your bottom line. Radwell gives you the opportunity of adding dollars andbottom products you don’t need. In many to your line. cases, selling your excess inventory to Radwell gives you the opportunity of BENEFITS - Lower warehousing adding dollars costs to your bottom line. - Lower warehousing costs

BENEFITS

- Increases cash flow

Increases cash flow - Liquidate aging inventory Liquidate aging inventory - Liquidate slow-moving inventory Liquidate slow-moving inventory - Eliminate used or overstock inventory Eliminate used or overstock inventory - Increases warehouse space Increases warehouse space A better option placing in a dumpster A-better option thanthan placing it in aitdumpster - Go Green Go Green

BENEFITS

• Lower warehousing costs • Increases cash flow • Liquidate aging inventory surplus inventory us gives Selling youryour surplus inventory to us to gives you a you a •Selling Liquidate slow-moving inventory financial return on products normally financial return on products you’dyou’d normally pay pay to have it disposed of.used Radwell’s Recovery have it disposed of. Radwell’s Asset Recovery •to Eliminate orAsset overstock inventory Service always provides FREEFREE freight service for for Service always provides freight service • Increases warehouse space your surplus stock. your surplus stock.

Radwell.com Radwell.com Radwell.com 5/22/2020 4:20:26 PM

5/22/2020 4:20:26 PM

Radwell-FC-01-2022.indd 1

12/16/21 3:32 PM

FIND SEPT. 12-17, 2022 • MCCORMICK PLACE, CHICAGO

Technology demonstrated by Mazak MegaStir

HYBRID MACHINING

DIGITAL MANUFACTURING. IMPLEMENTED.

EXPERIENCE THE POWER OF HYBRID MACHINING

MAZAK MEGASTIR Hybrid multitasking technologies can add immediate value through efficiency increases inherent in additive, hotwire, gear turning, and friction stir welding. Experience Mazak MegaStir and the complete Mazak Hybrid product line at IMTS 2022.

To ls available in horsepowers ranging from .3 hp to 3 hp,with spe ds ranging f r o m 3 , 2 0 R P M t o 1 0 , 0 0 R P M . WE LISTEN. WE OBSERVE. WE OPTIMIZE. n

WE LISTEN. WE OBSERVE. WE OPTIMIZE. WE LISTEN. WE OBSERVE. WE OPTIMIZE.

DIE GRINDERS & DIE GRINDERS & DISC SANDERS DISC SANDERS DESIGNED FOR PEAK EFFICIENCY

DESIGNED AND LONG FOR LIFEPEAK EFFICIENCY AND LONG LIFE

DIE GRINDERS & PROUDLY DESIGNED, ENGINE RED, AND BUILT IN AMERICA SINCE 1969 DISC SANDERS DESIGNED FOR PEAK EFFICIENCY

Durable, American made air tools are ideal for rapid material removal, deburring, finishing and polishing. Durable, American made air tools are ideal for rapid Straight-Line, Rightdeburring, Angle andfinishing 7° Offsetand models material removal, polishing. offered in front and rear exhaust configurations. Straight-Line, Right Angle and 7° Offset models Tools from offeredavailable in front in andhorsepowers rear exhaustranging configurations. .3 hp to 3 hp, with speeds ranging Tools available from 3,200 RPMintohorsepowers 100,000 RPM.ranging from .3 hp to 3 hp, with speeds ranging Contact for toa Free from 3,200usRPM 100,000 RPM.

Dynabrade,Inc. | 1.80 .828.73 3 | dynabrade.com | n

n n

Tool Demonstration! Contact us for a Free Tool Demonstration!

PROUDLY DESIGNED, ENGINEERED, AND BUILT IN AMERICA SINCE 1969

Dynabrade, Inc. | 1.800.828.7333 | dynabrade.com |

PROUDLY DESIGNED, ENGINEERED, AND BUILT IN AMERICA SINCE 1969

Dynabrade, Inc. | 1.800.828.7333 | dynabrade.com |

Dynabrade_IMD_Sept2021.indd 1

8/19/21 8:37 AM

Table of Contents

COLUMNS

10 14

BUSINESS 4.0 Marketing for Manufacturers: Let Your Customers be your Marketers

TALKING SHOP Mike Ricketts Western Midwest Regional Manager — SUHNER Machining

22 FEATURES

22 24

MANUFACTURING SHOWCASE The Cutting Edge of Aerospace Machining: Ensuring Parts are Precise and Reliable for Critical Applications

16 16

INDUSTRIAL FABRICATION & AUTOMATION

By: Walt Swietlik, Rite-Hite Customer Service and Support — Restraints, Levelers, Dock Communication Systems

8 Questions for Better Plasma Cut Parts By: Michelle Avila, Hypertherm Inc. Communications Manager

WORKFORCE DEVELOPMENT Recruitment, Retention and Development Remain Critical for Competitiveness By Jeannine Kunz, Vice President, Tooling U-SME

NEW TECH Lost in Logistics No More! Scalable robotic automation helps navigate the way to productivity By: Chris Ruelle, Key Account Manager at Yaskawa America Inc. – Motoman Robotics Division

PROCESS 100% Inspection High-Speed Non-Destructive Ultrasonic Scanning Identifies Minute Defects in Specialty Metals and Alloys

INDUSTRY INSIGHTS 10 Inventory Must Do’s for Small to Medium-Sized Manufacturers By: Adam Grabowski, Director of Marketing, Global Shop Solutions

4 | IMD

MARCH 2022

SAFETY & MAINTENANCE Ensuring Safety, Reliability, And Productivity At The Loading Dock

DEPARTMENTS

6 8 42 44 49 50

EDITORIAL DIRECTIONS INDUSTRY NEWS PRODUCT SHOWCASE ON EXHIBIT MODEX

CLASSIFIEDS ADVERTISER INDEX

ON THE COVER Cover Sponsor: Radwell International stocks and sells New and Surplus Industrial Automation, MRO, Pneumatic, Motion, Electronic, Hydraulic, HVAC and Electrical Control Equipment for plant floor and facilities maintenance machinery. Learn more at www.Radwell.com Cover Image by Suhner Industrial Products Corp. Suhner OWS, Orbital Sander. suhner-machining.com/en

SAFELY

Lifts Up To 500 lbs! Ergonomic Portable Lightweight Meets OSHA & ASME Requirements

Customized Safety Lifting Devices For Any Application

Available in both

CHAIN & CABLE Configurations

The Sky Hook is your personal safety lifting solution, preventing lifting injuries while saving you both time and money!

800-4-SKYHOOK 800-475-9466 • 208-365-5770

www.skyhookmfr.com

Editorial Directions Over the last six years of working with Industrial Machinery Digest, I have been fortunate to have had many firsthand experiences with leading manufacturers and experts within the industry. From technical demonstrations at various trade shows to onsite tours of production facilities, it has always been impressive to see not only where manufacturing was heading, but also what went into creating the tools, equipment, and software that was driving change. Logistics has caused issues that many of us have faced over the last couple of years. Supply shortages and staffing shortages have caused choke points for manufacturers and fabricators across the country. This is slowly improving but emphasizes the importance of having a fully developed understanding of your business’s inventory. This month, Global Shop Solution’s Adam Grabowski shares his thoughts on the must-dos for small to medium manufacturers to gain the insight they need to better manage their supply chain. Staffing shortages aren’t just tying up parts, supplies, and even products in ports and distribution centers. The ever-widening skills gap continues to add strain for many of our readers. SME has long supported workforce development. Their TOOLING-U program has provided tools and training solutions that have been available at in person events and even online. Jeanine Kunz, vice president of TOOLING-U, notes that while we have seen some progress, the impact of the previous year’s pandemic cannot be understated. You can learn more about her recommendations on not only recruiting new talent but the importance of retention as well in this month’s Workforce Development. Don’t forget to check out our improved Product Showcase and On Exhibit section. Now enhanced with the addition of QR codes that will connect you to more information with just the scan of your phone or mobile device.

SERVING AMERICAN MANUFACTURERS FOR OVER

North America’s Manufacturing Resource for Industry Professionals Since 1986

36 YEARS

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

Nick Boliek, Editor nick@indmacdig.com

Susan Rochester, Associate Editor srochester@indmacdig.com 800-366-0676 ext. 104 | Fax: 866-826-5918

Shane Bell, Creative Director sbell@indmacdig.com

SALES

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

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

Adrienne Gallender, Media Adviser agallender@indmacdig.com 888-407-7737

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

CIRCULATION & SUBSCRIPTIONS IMD, 3590-B Hwy 31 South, Suite 233, Pelham, AL 35124 circulation@indmacdig.com | Fax: 866-826-5918

REPRINTS To purchase article reprints please call 800-366-0676 ext. 103 or email wstrickland@indmacdig.com

Stay safe,

Nick Boliek Editor, Industrial Machinery Digest

source

360 media llc

A PUBLICATION OF:

Source 360 Media LLC 3590-B Hwy 31 South PMB #233 Pelham, AL 35124

INDUSTRIAL MACHINERY DIGEST (ISSN 1542-5223) is published 12x per year by Source 360 Media. POSTMASTER: Please send change of address to INDUSTRIAL MACHINERY DIGEST, 3590-B US Hwy 31 South, PMB 233, Pelham, AL 35124. Printed in the U.S.A. SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the U.S. to qualified individuals. Publisher reserves the right to reject nonqualified subscribers. Oneyear subscription to nonqualified individuals in the United States: $9600. Single copies available (prepaid only) $2000 each.

Alabama Automotive Manufacturers Association

6 | IMD

MARCH 2022

DRILL. TAP. REPEAT. Engineered Tough for Year After Year Reliability

Experts in Automatic Drilling & Tapping Units and Multiple Spindle Heads

HYPNEUMAT.COM • 414-423-7400

Industry News

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

Yu-Hsien Ho Promoted to Director of Channel Sales & Marketing for Cosen Saws

and we have a lot of confidence that Joe can support those technologies at the customer level and throughout our strategic partnerships,” commented Matt Schron, Jergens Inc. General Manager.

Yu-Hsien Ho has been with Cosen Saws for 14 years as of this year. He started in 2008 as a sales and marketing assistant and has held a number of positions in sales, marketing, and operations throughout the years. His previous role was Inside Sales and Marketing Manager, which he held for almost 6 years, and completed projects that grew sales and increased brand awareness. His move to Director of Channel Sales and Marketing is his most recent role, where he will focus on increasing sales in Welding Supply & Cutting Tool/MRO channels.

Alabama Community College System Opens Innovation Center, Starts Enrollment For Rapid Workforce Training The Alabama Community College System (ACCS) Innovation Center, a $10 million investment aimed at rapidly training workers for the state’s highest-demand industries, has launched its first of several industry-designed programs to help students find immediate employment. ACCS leaders, students and industry partners kicked off the Innovation Center’s opening and demonstrated some of the training at an event on Monday. The training includes short-term classes that students can start from anywhere in the state and finish with an in-person lab in a regional ACCS location. Once students complete their training, they are job-ready and are awarded a credential and an opportunity to earn more certifications at their local community college.

Jergens Inc. Appoints Joseph Farkas As National Sales Manager For Workholding Solutions Group Jergens brings on Joseph Farkas as National Sales Manager for its workholding solutions group as Ken Marvar looks to retire in April. Mr. Farkas comes to Jergens Inc. with more than 20 years of experience in sales development and management, as well as market channel strategies, for companies including The Timken Company, Fuchs, Sandvik and Kennametal. “Joe has proven himself in his career with impressive results for some of industry’s top suppliers and I am confident that he will also do a great job and take WSG to the next level,” says Ken Marvar. Mr. Farkas' timing coincides with key developments at the company. “Jergens workholding group has momentum in the market with recent advancements in top tooling and custom solutions, focused on 5 axis machining productivity,

Robotics Industry Pioneer Retires After Nearly Four Decades After nearly 40 years of promoting the growth of robotics in manufacturing, industry legend John Burg will be retiring from his sales role and as founder of Acieta. He plans to spend more time with family, go fishing, and work on his golf game. However, he will still be around the office occasionally to mentor Acieta’s sales team and offer consultation on special projects as Acieta’s Founder Emeritus. John began the company in 1983 while working as a machine tool distributor. He and his father, Marlo Burg developed a fascination with robots used in machine

IndustrialMachineryDigest.com

October 2021

IMPACTING DROP ZONE

the

m ineryDigest.co IndustrialMach

March 2019

Wildeck Provides Increased Safety for Moving Palletized Loads

www.IndustrialMachineryDigest.com 8 | IMD MARCH 2022

OWCASE: TURING SH MANUFAC

Inc. Cincinnati, STORIES: FEATURED Processes g Credential Streamlinin logy bal Techno Bringing Glo Level to a Local

» Empowering Employees » Surpassing Energy Savings Manufacturer in Oxnard, CA experiences the benefits of Green Hydraulic Power Units

» Lifting Higher Combi-PPT - A High Capacity Powered Pallet Truck

» Streamlining Control Siemens Offers Optimized Control Panel Construction to Machine Tool Builders

IndustrialMac hineryDigest.c om

June 2021

GETTING BACK TO WORK!! ESTABLISH ED IN 198 6

AND IS THE Most Ex INDUSTRY’ S nsiv Publicatte ion. e Industrial INDUSTRIA

L MACHI

NERY DIG EST

’S

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

shops, so they started Automated Concepts Inc. with eight employees and desktop computers. Over time, the company grew and advanced technologies by merging with other companies to eventually be named Acieta in 2014. Under Burg’s leadership, Acieta has grown to become one of the largest robotic integrators in North America. Over his career, he worked directly with thousands of clients to create a positive future for North American manufacturing.

GF Machining Solutions Announces New President of North America In line with its customer-centric growth strategy, GF Machining Solutions has appointed Chris Jones as the company’s President and Managing Director of North America. In his new position, Jones will play a pivotal role in further solidifying the company as the standard for intelligent machining solutions and as an industry leader in unparalleled service and support through operational and functional excellence. To advance the company’s 2025 growth strategy, Jones will expand its presence in vital market segments, including medical, aerospace, automotive/die mold, packaging, energy and consumer electronics. Within these markets, GF Machining Solutions will continue to provide manufacturers with innovative application-specific technologies. “My intent is to champion the customer and ensure that GF Machining Solutions is their most reliable and

trusted manufacturing partner,” said Jones. “Leveraging my team’s expertise and deep understanding of the challenges today’s manufacturers face, we will work diligently to provide them with the quality and service they need for success.”

Hunter Industrial Fans Names Seth Downing As National Account Manager As National Account Manager, Seth will oversee the industrial distribution sales strategy for Hunter’s Jan Fan Division by developing and executing product sales strategies and establishing key accounts on a national level. He will also be responsible for the administration and support of all customers in this vertical, which includes sales, marketing, logistics, and returns. Previously, Seth served as senior-level Marketing Manager at Apex Tool Group, LLC, supporting the Industrial Channel and specializing in the commercialization of all newly launched GEARWRENCH® products. As a National Account Manager, he supported two major automotive wholesalers where he consistently exceeded his growth targets year after year. With over ten years of experience in sales, marketing, management and product development, Seth has developed a unique ability to lead cross-functional teams, grow revenue, develop customer programs and execute promotional campaigns with measurable results.

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 9

Business 4.0

Johanna Boland Group Strategy and Communications Manager at ANCA CNC Machines

Marketing for Manufacturers: Let Your Customers be your Marketers

hen I moved into the Communications role at ANCA, an Australian manufacturing company, I anticipated our marketing activity would be straightforward, and, if anything, a little bit dull. I knew I would be working in the technology sector, and that was interesting, but I wasn’t sure how much creativity would be encouraged or needed in a B2B organization. And to be honest that is what I found. We are a fully privately-owned Australian manufacturer running for over 45 years from Melbourne and export 99 per cent of our product overseas. ANCA is thriving with around 1,000 employees and is a world leading manufacturer of CNC grinding machines, motion controls, sheet metal solutions and components. We have customers in over 45 countries and facilities in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a network of representatives and agents

10 | IMD

MARCH 2022

worldwide. So as a business ANCA was doing well. My first job was to benchmark against our competitors, and we were easily meeting the same standards. We had a strong brand, advanced product management process, advertised, participated in the right exhibitions, produced good, printed sales materials and had a passable website. All respectable, solid traditional marketing activities. But it wasn’t just traditional marketing that enabled us to take the top position in our market. We make a really great product with extraordinary technology backed up by a global sales and service infrastructure. It was a positive customer experience that saw us dominate our market. We were successful and our customers loved us – so why break what wasn’t broken? Finding my feet, I realized the potential of this opportunity. With a more progressive marketing strategy we could offer

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

greater customer value and stand out in our market. We wanted to be progressive in channels but also in our approach and content. Firstly, we considered the customer experience and from reviewing social media, I got a very strong sense of the people behind the machines. These cutting tool manufacturers considered themselves as craftspeople who made objects just as beautiful and refined as a guitar. Tapping into this passion and profiling the person as well as the technology has differentiated us compared to our competitors. Telling our users’ stories has helped us better engage and inform customers. We also looked at our channels and digital was the one to tackle first. Our website was old and clunky – but again, against our sector we were not doing badly. The business wasn’t shouting for a new website, but with dated architecture and visuals the site wasn’t the perfect match for our brand. We boasted technology that could grind to an accuracy of <0.002 millimeters, yet our website was over ten years old, and looked it.

In our new website we have a careers section to highlight how cool ANCA was to work for, video integration for highlighting new products, a news and media section to add value for our customers and it is integrated to our customer relationship management system (CRM) for lead generation and visibility. Our next step will be to launch an e-commerce platform in a few months – something I am sure our competitors are not ready for and which will further help position us as a progressive business and grow revenue. Our content marketing not only adds value to the customer but it also profiles our experienced technical experts and reinforces ANCA’s brand as the leader in its field. Social media has also provided important access to the voice of customer and our Product managers regularly use the global Cutting Tool Facebook Forum to seek customer insights and understand what the market is thinking. We were the first in our industry to really have a go at social media and are now streaks ahead of our competition in both followers and engagement. In fact, our competitors are copying our

• Fer ous & Non-Fer ous Cold Saw Models • Manual to Ful y Automatic • Financing Available

When CuttinG Tube SPEED & Precision

MATTER When CuttinG Tube SPEED & Precision

MATTER

Convenient & Free. We bring Scotchman machinery to your location. See them in action & test cut your material without leaving your place of business, anywhere in the lower 48. Scan QR code or call.

• Ferrous & Non-Ferrous Cold Saw Models • Manual to Fully Automatic • Financing Available

PROUD AMERICAN MANUFACTURER EST. 1967 PROUD AMERICAN MANUFACTURER EST. 1967

(800) 843-8844 www.scotchman.com

Convenient & Free. We bring Scotchman machinery to your location. See them in action & test cut your material without leaving your place of business, anywhere in the lower 48. Scan QR code or call.

(800) 843-8844 www.scotchman.com

Scotchman IMD Half Page Ads 2022.indd 1

2/9/22 3:09 PM

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 11

campaigns in their own social feeds. Thankfully it is much easier to start in front than to catch up. Posting regular content and engaging with customers’ posts has built a thriving community. We see tons of fantastic user generated content with customers sharing photos of the tools they have produced on our machines every day. Using the hashtag #MadeonANCA, we now have hundreds of mini customer testimonials that give meaningful credibility to our brand. Going back to the people behind the machine, we prioritized activity to improve the customer experience, rather than selling the product. Our #ToolTipTuesday series has been a hit.

12 | IMD

MARCH 2022

We post a short informative video with tips on how to use our software. These videos have attracted almost 85,000 views on YouTube since launch. A sales person recently had a call from Boeing asking about a machine after seeing a tool tip which piqued their interest. Given our machines can sell for hundreds of thousands of dollars, this was a cost-effective sales lead. Our #ANCAFlashBackFriday posts spark conversations about past achievements and memories to help reinforce our heritage and brand loyalty. We are also about to launch our own TV show — ANCA Academy — to host on our YouTube channel. What I am most proud of is our Tool

of the Year competition, which is now in its fourth year. The team built a campaign that has attracted over 100 entries from

Turkey, India, Italy, France, Thailand, USA, Germany, Poland, China, Russia, Japan, Korea and Malaysia. We livestream the results at the major trade fair of the year and gain significant media coverage to boost our customers’ brands. Last year there were almost 30 entries received from across the world, achieving 70 media appearances seen by over 80,000 fans and generating over 200,000 engagements on social media. Awards are not a new concept, but this format was for our industry, especially using social media as part of the campaign. We use our Facebook channel for the community to like the entries and select the finalists, helping grow our own Facebook page and reach a broader audience. We found an influencer, Alfred Lyon, and asked him to be a judge. Alfred is a customer in the USA who has over 45 thousand followers on Instagram – and I don’t imagine that many people would bother to follow if they weren’t interested in content featuring cutting tools. At a trade show in Germany when we announced the winner on the stand, a customer came up to me and thanked me for giving their industry a platform to be recognized. Four years into working for ANCA I have seen the value of thinking creatively and bringing new and different ways of building your brand to a business. Traditional marketing remains fundamental, but building a personality around

our product, telling a story and considering the person behind the machine has helped us gain a more vibrant and open reputation. ABOUT ANCA: ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide. ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical. For more information, visit machines.anca.com

Innovation, Quality & Performance Backed By Decades Of Experience Pipe & Rebar Benders, Ornamental Benders, CNC Controls, Custom Machines & More! Section Plate Rolls Angle Rolls Benders JUST ROLL 1” to 10” 30 Models Custom Machines CNC Options

20 Ga to 6” Capacities, 80 Models CNC Options

WITH IT!

Heavy Duty 1" to 3" Capacities Twist Options Available

Visit Our Website Or See Us Online At :

(251) 937-0947

sales@carellcorp.com • www.carellcorp.com sales@eaglebendingmachines.com • www.eaglebendingmachines.com

MEMBER

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 13

Talking Shop

SUHNER offers engineering, technical support, and a complete service center here in the U.S.

FEATURING:

Suhner OWS, Orbital Sander.

TALKING SHOP WITH: Mike Ricketts — Western Midwest Regional Manager — SUHNER Machining How would you describe your company's primary business? Helping manufacturers with their success—critical metal component machining needs that include drilling, milling, honing, chamfering, reaming, cutting, and tapping into steel, aluminum, alloys, fiber glass, foam and other materials.

In brief, what is your history with the company?

regionally. Our goal is to support our customers manufacturing needs quickly and easily with our ‘care’ programs (stocking MRO supplies on-site and providing support).

What are interesting applications of your products?

Because of the rising needs of the market and our customers, SUHNER has launched a range of Robot end-effectors for material removal and polishing.

Over the last few years, SUHNER has helped the Trailer Industry with their manufacturing needs.

For more information, visit www.suhner-machining.com/en/

I bring almost 23 years of industrial automation experience to the table. I have been with SUHNER nearly five years as their Western Midwest Regional Manager for the Machining Division based out of the Chicagoland area. I have developed relationships with companies ranging from Fortune 50 companies all the way down to local contract manufacturers in main industrial verticals (i.e., Large and Small Commercial Trailers, Automotive, Aerospace and Foundries to name a few).

What critical issues are often overlooked by your clients that they have or might encounter?

How has your company changed through the years?

Some of the key advantages we offer is our local representation. SUHNER offers engineering, technical support, and a complete service center here in the U.S.

SUHNER has become much more focused to the needs of their customers globally as well as

14 | IMD

MARCH 2022

What are you excited to bring manufacturing professionals in 2022?

One of the primary issues overlooked often is what type tooling our client would need to be using and how to incorporate it within the spindle application. We can’t stress enough the need to get a tooling expert involved early in the project to recommend proper tooling for the application.

What are the key advantages you provide to small-to-medium manufacturers?

Suhner EconoMaster Spindle units with custom motor housings.

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

Dedicated to Robot Solutions

The SUHNER ROBOTools for fully automated manufacturing For stationary machining applications, SUHNER products already represent the first choice. However, in cases where the cutting tool must be moved towards the work piece, insufficient or not, many practical solutions are readily available. This gap is now being closed by the SUHNER robot machine tool program. One option is to bring the work piece towards a standard stationary SUHNER machining unit. Today, SUHNER offers the possibility to adapt and guide the tool by the robot. As a specialist in automation processes, machining units, handheld power tools and abrasives, SUHNER has expanded its wide product range with special tools that can be mounted directly to the robot arm and ready for continuous industrial use. In short, SUHNER has multiplied the capabilities of the robot to now include surface finishing. The application range is enormous.

Change of the abrasives Abrasives typically have a short life cycle. A patented, simple quick change of abrasives system (dispose and reload) was added to the program to simplify the change of abrasives. This quick change for abrasive system from SUHNER, for example, allows the use of different abrasives in sequence to achieve a desired surface finish. An automated

abrasive change increases the flexibility and eliminates unproductive production hours.

Servo motor driven angle grinders Today, most robot guided grinding and polishing machine tools are operated by air. Often, considering a 24-hour operating environment, these machines reach their limits. Frequent service interruptions, plus extremely high air consumption add to energy cost that also will affect profitability. In addition, air driven tools drop in speed when under load which can contribute to an adverse effect to the surface finish. Depending on surface quality requirements, the rotation of the grinding or polishing tool often requires clock and counter clock rotation which an air driven tool can’t accomplish. All of these critical requirements can be met with the newly designed servo driven tools from SUHNER either in standard or orbital design version. Lightweight and powerful servo motors are used to obtain high speeds up to 9,500RPM made for continuous operation. All grinding tools are made with an M14 spindle to enable the use of standard, commercially available grinding discs. For more information, visit https://www.SUHNER.com/en/robotics/

LIKE YOUR BIG VMC’S APPRENTICE CNC MILLS | CNC LATHES | CNC PLASMA TABLES | CNC ROUTERS | AUTOMATIC FEED BANDSAWS

Prototype. Run second operations. Perform short-run production. With its compact size, the 1100MX sneaks into unexpected places. With servo motors and a BT30 spindle, it’s built to mill anything. Set it up and start making chips and cutting parts. At Tormach, we help people make things. Our 1100MX runs on our intuitive and easy-to-use CNC controller, PathPilot®. For a lot of our users, PathPilot is a dealmaker. Start cutting for $21,450, or deck it out with an optional ATC and PathPilot Operator Console.

What do Tormach owners love about Tormach? • Maintain your right to update, upgrade, and upkeep. • Buy-what-you-need, upgrade-as-you-go modular equipment. • Experienced machinists make up our USA-based Tech Support crew.

Learn more and build yours at tormach.com/1100MX/IMD INDUSTRIAL MACHINERY DIGEST.COM

IMD | 15

Safety & Maintenance

Walt Swietlik Rite-Hite Customer Service and Support Restraints, Levelers, Dock Communication Systems ABOUT THE AUTHOR Walt Swietlik has more than 35 years of experience in the material handling industry, with more than 30 of those dedicated to the area of loading dock and door safety and improved productivity. For the past two decades, Walt has managed Rite-Hite’s popular “Customer Fly-In Program,” where he works closely with a variety of customers to address the challenges associated with shipping and receiving areas. Walt’s experience has put him in close contact with many customers from many industries with unique safety and loading dock safety challenges. As a result, he has become a noted expert on issues related to shipping and receiving and ensuring safe and efficient material flow across critical loading docks throughout customer's supply chains. Walt has spoken at a variety of local, regional, and national forums, including ProMat and MODEX.

16 | IMD

MARCH 2022

Ensuring Safety, Reliability, And Productivity At The Loading Dock

he loading dock can be one of the most dangerous parts of any facility, with trailers constantly being loaded and unloaded and forklifts moving heavy pallets amid workers on foot. Unfortunately, safety precautions in this busy part of the plant are often overshadowed by more obvious hazards inside the plant, such as cutting, welding, and other machining equipment. Protecting workers—and the goods and equipment that are part of these processes—is one of the most fundamental aspects of any facility manager’s job, so overlooking loading dock safety can be a fatal mistake. However, by investing in the right loading dock products and dock management software, facilities can seamlessly build safety into their shipping and receiving operations, while also improving productivity. Here’s how:

Reliability with the Push of a Button Loading dock products must be equipped or designed to tolerate heavy loads and endure in-plant vehicles such as 3- and 4-wheel forklifts and automated guided vehicles (AGVs)—plus the weight of the materials being transferred— running over it daily. It’s imperative this equipment is sturdy and reliable. Central to any loading dock operation is the loading dock leveler. This piece of equipment bridges the gap from the facility floor to the bed of a trailer during loading and unloading. Beyond its most basic function as a bridge for forklifts, it should also have safety and ergonomic features built into it. Hydraulic loading dock levelers can be lowered or raised with a push-button instead of workers having to use a pull-chain, which could add long term safety concerns (like back problems) for employees operating this heavy equipment. Levelers that offer a smooth transition from floor to leveler to trailer and back are also preferred, since the “dock shock” caused to forklift drivers by bouncing across poorly designed

e d a M n merica KES

BRA 1972 S S E R P Since SHEARS & ! ATALOG C E E R RAF CALL FO

Hydraulic Shears:

1/8” (10GA), 3/16”, 1/4”, 3/8”, 1/2”, 5/8”, 3/4”, 1” and 1-1/4”

Press Brakes: 50-Ton to 550-Ton

C-Frame Presses:

40-Ton to 200-Ton

Custom Designs:

for Custom Applications

Retrofit Backgauges:

for Shears and Press Brakes. Made to fit most machines with minimum modifications.

Precision Knife Sharpening

Phone: 319-435-2378 | Fax: 319-435-2262 | sales@betenbender.com | www.betenbender.com

levelers can cause chronic spinal injuries and other physical problems – not to mention breaking products. For vertical levelers, ideal for drive-through applications, a key consideration is using a sensor that disables the lowering function of the leveler if movement is detected in the pit area. This adds an additional layer of pedestrian safety during leveler cleaning, maintenance, and everyday use. In addition to the loading dock leveler, it’s important to have a strong vehicle restraint to secure a trailer to the building wall. Operators can engage a vehicle restraint with a trailer’s rear impact guard (RIG) using NEMA 4X controls from inside the plant instead of having to go outside to place unreliable, simple wheel chocks on the potentially dangerous drive approach. Wheel-based restraints can also be an automated operation if the application allows. A properly engaged vehicle restraint can help prevent a host of trailer separation accidents that can lead to risk to products, equipment, and—most importantly— injuries to material handlers. Using logistics equipment at the loading dock once required manual labor. Now, when equipment is interlocked into controls, it can be operated with the ease of a button push.

Interlocking Controls and Safe Sequence of Operation The development of programmable, interlocking controls at the loading dock adds another layer of safety. By combining the vehicle restraint, dock leveler, overhead dock door, dock barrier, and more, dock controls can be programmed to work only in a safe sequence of operation. This allows facility managers to help prevent accidents due to improper usage—saving facilities money, and costly downtime in the long run. Integrating multiple loading dock operations into a simple, centralized control system makes it easier for loading dock attendants to perform docking operations safely and quickly. For example, an interlock system disables the use of a hydraulic leveler, overhead door, or dock barrier until the vehicle restraint has achieved a safe engagement.

Eyes Outside - Boots Off the Ground Advanced loading dock controls can go beyond sensors and offer a live view of the critical safety points on the loading dock exterior. A monitor on the inside of the loading dock, using an exterior camera, can provide a real-time view of the vehicle restraint at the RIG or wheel, as well as at the nose of the trailer. This allows loading dock workers to see if the vehicle restraint has properly engaged with the trailer RIG or wheels, based on which application is used. When equipped with a dual camera, workers inside the loading dock can get a live view of the nose of the trailer to verify trailer stand presence in the case of dropped trailers. Confirming the vehicle restraint is engaged and/or trailer stand present eliminates the need for workers to go outside and manually check these products are working properly. In contrast to false alarms from presence-sensing

18 | IMD

MARCH 2022

devices, active monitoring from a camera can help keep boots off the ground and help prevent accidents on the drive approach. Additionally, workers might be able to see why a vehicle restraint goes into fault mode instead of having to diagnose the problem while potentially in harm’s way. As a standalone product, these outdoor cameras and indoor monitor can be incorporated into a loading dock area to provide the same benefits described above.

Clear Communication at the Loading Dock Red/green interior and exterior dock lights are the most ubiquitous tool for communication and safety at a loading dock. A green light on the control box inside indicates to a forklift that the trailer is locked and safe to enter, while the corresponding red light outside tells the truck driver it is not safe to pull away (and vice-versa). However, these interior lights are not always visible, as stacked pallets can obscure a lift driver’s view. Thankfully, advancements in LED light communication systems have addressed this issue – and more. Hazard recognition and control systems that incorporate the newest technologies can offer safety solutions inside and outside the loading dock area on the drive approach. This combination of components uses motion detection, line-of-sight notification, and audible alarms to provide hazard recognition and communication to people on and off forklifts. Working in tandem, these safety tools help create a safer, more productive loading dock environment, both inside and outside, by helping keep people a step ahead of the potential dangers in their path. Outside the dock opening, from a fixed location above the dock door, a sensor detects the motion of

a tractor-trailer backing into that dock position. A visual and audible alarm located in the vehicle restraint, or mounted as a standalone box, alerts dock workers on the drive approach of the impending danger. This multisensory alert system is particularly important because ambient noise often masks the sound of a cab’s noisy engine, which can be 70 feet or more from the back of the trailer. Inside the dock area, motionsensing technology can trigger a bright blue light that projects onto the dock leveler when it detects material handling equipment or a pedestrian’s presence inside the trailer. An advanced system also will work in conjunction with the vehicle restraint to alert any dock worker or forklift that enters an unsecured trailer. A blue light emits as an audible alarm alerts the unsuspecting dock worker that they’ve entered an unsecured trailer, while the external light system simultaneously changes to red, warning the truck driver that there is activity inside the trailer. If integrated properly with this safety system, the

vehicle restraint cannot be disengaged if motion is detected inside the trailer. Also on the inside of the loading dock are safety lights located just above the upper corners of dock door openings. These LEDs provide a second line-of-sight to the trailer restraint status in the event control box lights are

LIFTING AND MORE

Our selection of Permanent and Electro magnet lifts cover a wide range of steel lifting applications. We also specialize in custom lift solutions designed specifically for your application.

INDUSTRIAL MAGNETICS, INC.

231.582.3100 • 888.582.0822 • WWW.MAGNETICS.COM MORE THAN A MAGNET COMPANY INDUSTRIAL MACHINERY DIGEST.COM

IMD | 19

obscured by pallets. There are also LEDs located in the corners of the leveler to let workers inside the trailer know the trailer restraint’s engagement status, warning them to leave immediately if the restraint becomes disengaged. While LED communication at the loading dock isn’t new, it’s often a good starting point for any facility that simply has a red light/green light on the inside and outside of the loading dock. Upgrading to smart equipment in this part of the facility today can reap benefits in the future if a move to an Industrial Internet of Things (IIoT) platform is made down the line.

Industrial Internet of Things and Dock Management Software Getting the right smart equipment at the loading dock can boost productivity while enhancing safety. When connected through dock management software as part of an Industrial Internet of Things (IIoT) platform, loading dock managers can more clearly see the constantly shifting nature of this busy part of the plant. This focus allows companies to increase energy efficiency, streamline communication, enhance productivity, and monitor events. Real-time and historical safety events can be communicated to safety managers through text and/or email alerts. Through an analysis performed by the IIoT platform, this data helps companies proactively identify trends, training opportunities and employee behavioral improvement through data-driven decisions. There are various IIoT platforms able to tap into tremendous amounts of data provided by smart-enabled equipment at the loading dock and inside the plant. Some go beyond capturing data to provide managers with operational insights that help eliminate risky patterns and procedures. Such data analysis can help managers determine if intersections in a facility are becoming too congested or if a mistakenly opened dock door are isolated incidents or recurring problems that need to be preemptively addressed before a devastating accident occurs.

Achieving a Safer Loading Dock One of the main goals for any facility is to make it through the day without an injury. While the loading dock is a necessary component for the logistics operation of any successful facility, it can be an area fraught with danger.

20 | IMD

MARCH 2022

However, recent technological advancements made at the loading dock are making it easier than ever to help improve worker safety. Implementing strong and reliable equipment is the first step in delivering a safer work environment. Enhancing that equipment with advanced controls and communication options can even further safety at the loading dock. Taking the next leap into dock management software will bring a new way to streamline communication and operations at the loading dock. All these loading dock products combine to demonstrate that worker safety and operational productivity truly go hand in hand. After talking with their local loading dock equipment representative, facility managers and safety managers will be on the right track to help send their employees home safely every day. ABOUT RITE-HITE Rite-Hite is a world leader in the manufacture, sale, and service of loading dock equipment, industrial doors, safety barriers, HVLS fans, industrial curtain walls, and more - all designed to improve safety, security, productivity, energy savings, and environmental control. Watch Rite-Hite's Always Looking Ahead video below to learn more. For more information, visit www.ritehite.com The information provided herein is provided as a general reference regarding the use of the applicable products in a specific application. This information is provided without warranty. It is your responsibility to ensure that you are using all mentioned products properly in your specific application and in accordance with all laws and regulations.

A DE I N T H

US A

100%

The Best Tool Cabinet You Will Ever Buy GUARANTEED IN

E V E R Y W AY

MADE BY AMERICAN CRAFTSMEN IN THE USA

WWW.STORLOC.COM • 1-800-STORLOC 1-800-786-7562

sales@storloc.com

Manufacturing Showcase

The Cutting Edge of Aerospace Machining: Ensuring Parts are Precise and Reliable for Critical Applications From rapid prototyping and design for manufacturing before the first part is machined, to adaptable and scalable manufacturing and state-of-the-art metrology & inspection throughout the process

or the aerospace industry, the “cutting edge” of parts machining goes far beyond having the latest CNC equipment and accessories. It also means engaging at the earliest stages of the process using the latest in design for manufacturing (DFM), simulation and process verification processes prior to cutting the first part. It is then critically important to have flexibility and adaptability to make changes and scale production when needed with the ability and commitment to inspect with the most precise tools throughout the process. The goal of this approach is to give customers the knowledge that when machining begins, the parts are going to be 100% right, with zero defects, the first time and every time. Delivering this level of peace of mind is critical in the aerospace industry. There is, after all, so much at

22 | IMD

MARCH 2022

stake in aerospace and defense where parts are critical to performance and safety. Whether operating in the air, sent into space, or used on the battlefield, the reliability of how parts function is essential to success. Typically, when a potential customer is looking for a machine shop to make a complex part, they are looking for the latest equipment and current certifications including ASQ, ISO 9001 and AS9100. There is a tremendous benefit, however, for a customer to look beyond these prerequisites for a machine shop that will work with them from the design phases through manufacturing to predict and resolve failures before they happen. The ability to predict when failures could occur requires proactive communication and early engagement with an expert machine shop.

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

Design For Manufacturing – The Ability To Adapt Early A Design for Manufacturing process enables the machine shop to anticipate possible complications and limitations in the machining process upfront. “With Design for Manufacturing, the goal is to make the product manufacturable in an efficient and cost-effective way and that starts with reviewing the parts and discussing the specifications openly,” says Tony Doan, CEO of San Jose, California-based Halcyon Manufacturing, an advanced ITAR Registered and AS9100/ISO9001- Certified manufacturing shop for complex parts serving Greater Silicon Valley. “The aerospace and defense industry needs a cutting-edge machine shop that has both the expertise and the desire to guide their customers on how to achieve better machined products at a better price.” This analysis and feedback are part of an ongoing manufacturing collaboration between an aerospace client and their contract machining partner well before production starts from the inception of a project through prototyping. Halcyon applies the Design for Manufacturing protocol across a wide spectrum of metal machining from bar grade 6061 aluminum, brass, copper, titanium, stainless steel, and plastics. The company also works with quartz, ceramic, graft, titanium, and a variety of steels and serves customers in the aerospace, home defense, automotive, medical, and semi-conductor sectors. “When you can use the latest simulation and process verification technologies prior to cutting the first chip of metal or plastic, then when you start manufacturing, you know that the parts are going to be 100% right the first time, every time,” says Doan.

Rapid prototyping Rapid prototyping removes financial and time risk by providing a cost-effective way to test a full range of designs and materials. With rapid prototyping, many iterations of a part may never make it to production, which can save aerospace and defense contractors time and money. “If we understand how the part needs to function, we can 3D print the item in plastic, run it through a few tests, and then proceed – rather than rush to machine parts out

of expensive material in the prototype phase,” explains Doan, who adds that in addition to initial prototyping, 3D printing can be used to create workholding and fixtures.

Adaptability And Scalability In Production Aerospace and defense clients operate in highly dynamic markets and the need for changes to part specifications and the quantity of parts is high. Cutting-edge aerospace machine shops must therefore be adaptable and flexible for any design changes. They also must be capable of scaling up production to “lights out” manufacturing if needed without compromising the accuracy of the machining. “While capacity is certainly important, the overall size of a machine shop is not the most important criterion,” says Doan. “Aerospace and defense companies certainly need manufacturing scale, but they also require adaptability as complex manufacturing designs evolve and change. For a machine shop to be an effective partner, they need to be nimble.”

Inspecting Quality Upfront Finally, to complement the machining capabilities and nimbleness, a shop must have state-of-the art metrology equipment for advanced inspections guided by a proactive zero-defect mindset. “It’s not about making parts and sorting out the bad ones and shipping the good ones,” says Doan. “You need a machine shop committed to not making the bad parts at all.” “To produce the most precise parts, you must be able to inspect more than the finished goods,” he adds. “A machine shop should be inspecting in real-time such things as the set-ups and the speed throughout the process which enables data to be captured for statistical predictive process control.” At Halcyon, automated coordinate measuring machines (CMMs) perform process inspections and produce first article reports. Halcyon also uses a digital multimeter (DMM) with scanning capability that can take thousands of data points during a scan of a complex curved surface. This results in very precise and accurate repeatable product evaluations.

Forging A Partnership Aviation, defense, and other sectors that rely on machine shops to produce precision parts to extremely tight tolerances with consistency should look beyond the basic certifications and CNC capabilities for those with the expertise to optimize the manufacturing process before any items are manufactured and adjust as needed after. With this level of flexibility, and by ensuring a zero-defect approach at every stage of the process, OEMs and defense contractors can proceed with certainty that the parts they are receiving are of the highest reliability and without unnecessary additional costs for their most critical applications. For more information visit the Halcyon website at www.halcyonmfg.com or call (408) 231-3124. INDUSTRIAL MACHINERY DIGEST.COM

IMD | 23

Industrial Fabrication & Automation

8 Questions for Better Plasma Cut Parts

By: Michelle Avila, Hypertherm Inc. Communications Manager

uestions about cut quality and consumable life are common when cutting with plasma. How’s my cut quality? Are my consumables lasting long enough? Is there anything I can do to improve my productivity? Unfortunately, there isn’t one simple answer to the above questions because so many factors impact the outcome you will see. Although Hypertherm’s Technical Service Team is happy to help you troubleshoot issues, customers can often achieve the same results by asking the following eight questions.

1. Are You Cutting in The Right Direction? With standard consumables, the plasma arc spins clockwise as the torch moves forward into the cut. This means the squarest cut angles will be on the right side of the arc. To benefit from this, cut contour shapes in a clockwise direction and holes and other internal features in a counter‑clockwise direction.

24 | IMD

MARCH 2022

2. Are You Following the Cut Charts? Sounds like a simple question, right? Still, we often come across customers using the wrong settings. Look at your owner’s manual. Refer to the cut charts and make sure you are using the

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

settings listed for the material type, material thickness, desired cut quality, and speed you want. The cut charts will tell you what consumables to use, what plasma and shield gas you need, and give you the appropriate gas pressure (or flow rates), torchto-work distance, arc voltage, and cutting speed.

of the cut edge. This kind of dross is easy to remove and flakes off the plate. To eliminate it on future parts, cut faster. On the contrary, high-speed dross causes a thinner bead of molten metal to collect at the bottom of the cut. To fix this, slow down your cutting speed so the arc has time to catch-up with the torch.

3. Are You Using Good Consumables? Any type of imperfection on your consumable parts can impact system performance so you want to regularly inspect your consumables and replace if needed. Though less common, we also sometimes discover customers who have accidentally put the wrong consumables into the torch. If you continue to have cut quality issues, we suggest double checking the laser-etched part numbers found on each consumable with the numbers in your owner’s manual.

7. How is your air or gas quality?

4. Is Your Torch Square to The Workpiece?

8. Does your table need a tune-up?

Torches can sometimes get knocked out of alignment. If you find that you need to adjust your torch, check to make sure your table and workpiece are level and that your table slats are not covered in dross. Keep in mind that if the metal plate you plan to cut is bent or warped, it might be impossible to square the torch.

Is the table cutting at the specified speed? Is the torch secured tightly to the table gantry? How is your table motion? Is it vibrating? Often, plasma cutting issues have nothing to do with the plasma itself and instead are caused by poor motion or other table issues. If you’ve run through the preceding seven questions and are still having issues, it might be time to reach out to your table manufacturer.

5. Are you holding the right torch to work distance? Sometimes referred to as a “stand-off,” you’ll want to ensure your torch isn’t too close or far from the workpiece as this will cause angled and rounded cut edges. In addition, if the torch is too close, metal spatter blowing back onto the torch can seriously damage your torch and nozzle. Lastly, don’t forget to routinely adjust the torch to work distance as your consumables wear.

6. Are you cutting at the right speed? Dross is a great visual clue that lets you know if your cut speed is too fast or too slow. Low-speed dross is the bubbly or globular molten material that collects at the bottom

If using an air plasma, make sure your air is clean and dry. The same applies to your gas when using an oxygen or multi-gas system. Always use pure, high-quality gas and the appropriately sized regulators and gas lines. If a manual purge is required, confirm that the purging cycle was completed. Check to see if gas is leaking or flow is restricted. Ask your gas distributor for help if needed.

ABOUT HYPERTHERM Hypertherm engineers and manufactures industrial cutting products used by companies around the world to build ships, airplanes, and railcars, construct steel buildings, manufacture heavy equipment, and more. Its products include cutting systems, CNCs, and software trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. Founded in 1968 and based in New Hampshire, Hypertherm is a 100 percent Associate owned company, employing more than 1,800 Associates, with operations and partner representation worldwide. Learn more at www.hypertherm.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 25

Workforce Development

Recruitment, Retention and Development Remain Critical for Competitiveness By Jeannine Kunz, Vice President, Tooling U-SME

t’s now two years into a pandemic that has disrupted the entire world. The arrival of COVID-19 caused manufacturers to scramble to rethink their businesses and address major financial, operational, and staffing challenges. Certainly, Covid-19 has added a layer of complexity to the challenges around recruitment, retention and development that exist in the manufacturing industry.

Long Predicted Skills Gap Let’s go back even further to look at the skills gap that was developing a decade ago—and how that plays into our human capital situation now. Back in 2011, despite high general unemployment, a critical shortage of skilled workers threatened the future of manufacturing in America. Tooling U-SME—and other experts—predicted that if the skills gap was not immediately addressed, the crisis would dangerously accelerate in the next decade. We knew that between rapidly changing industrial technology and the pending retirement of millions of baby boomers, the manufacturing industry was going to be hit by a serious depletion of talent. At the time, we surveyed hundreds of manufacturers through our Workforce 2021 Readiness Assessment tool, and uncovered three areas that needed to be immediately addressed:

26 | IMD

MARCH 2022

1. Finding incoming employees 2. Training incoming employees 3. Upgrading the skills of incumbent employees to keep up with changing technology These priorities haven’t changed. Here we are, a decade later, and we are in a workforce development crisis. We were seeing some progress. Throughout the last decade, manufacturers have built momentum as they started creating and sustaining a strong talent pipeline. Strategies having a positive impact include: » Onboarding programs » Standardized on-the-job training (OJT) » Defined career pathways » Apprenticeships » Competency models » Strong educator connections (K-12 plus two and four-year educational institutions) » Online training

Covid-19 Arrives Then, in early 2020, Covid-19 arrived, and changed the workforce. The pandemic hastened retirements as many older employees did not want to risk infection by working onsite.

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

All industries, from foodservice to retail, lost employees. For some, remote education for children meant parents couldn’t work outside the home. Others didn’t want close contact with customers. Some employees found new jobs working from home. Today, competition for employees is fiercer than ever. A Gallup study shows 48 percent of employees are actively looking to make a change. And there are millions of job openings. US manufacturing is expected to have 2.1 million unfilled jobs by 2030, according to a Deloitte/ The Manufacturing Institute study. With salaries and incentives increasing across all industries, manufacturers are just one more option for candidates looking for new jobs. Small and medium-sized manufacturers have especially been hit hard.

Smart Manufacturing Momentum At the same time, there has been another shift in the industry. The pandemic has helped the manufacturing community realize it is time to accelerate the move to Smart

Manufacturing. Companies have moved toward automation and robotics for health and safety reasons as well as to retain productivity despite, in some cases, fewer workers onsite. Yet, manufacturers are at drastically different stages and of varied mindsets. Recently, to help manufacturers at all stages, SME and CESMII – The Smart Manufacturing Institute, announced a partnership to drive Smart Manufacturing further and faster by aligning resources and educating the industry, helping companies boost productivity, and build a strong talent pipeline.

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 27

As Robert Willig, CEO, SME, said, “Together, CESMII and SME will optimize our strengths and resources to accelerate the transformation and democratization of the Smart Manufacturing ecosystem and jumpstart productivity.” Together the two organizations are addressing the “digital divide” by connecting manufacturers to technical knowledge. These efforts will especially help small and medium-size companies—a large part of the supply network—to overcome the cost and complexity of automation and digitization that has constrained productivity and growth initiatives. We are committed to ensuring small and medium-sized companies are prepared to deal with the daily challenge of recruitment, retention and upskilling to ensure their teams are prepared and trained to tackle a shift to Smart Manufacturing. This is critical so they are not left behind. Larger manufacturers need their supply chain partners to have the capabilities to integrate with their digital systems. If that doesn’t happen, they will select companies that do. The gap between those innovating using SMART technologies and those who don’t will continue to grow— and there may be no catching up. For optimum success, it is important to invest in employees so that they have the right knowledge and skills covering advanced technology topics. This ensures they know how to use the new equipment to its full potential. Then they can excel and innovate, allowing them to grow in their careers.

28 | IMD

MARCH 2022

That’s why one of the first initiatives of CESMII-SME partnership is focused on manufacturing workforce education. The program will leverage the extensive reach into industry and academia that we have at Tooling U-SME. In addition, the combined training portfolios of both organizations and new content collaborations will expedite Smart Manufacturing adoption, driving progress through transformational workforce development.

Optimizing Training Through Technology At Tooling U-SME, we have already been taking action to help build awareness for the importance of starting this SMART journey – and providing tools to help. We offer dozens of online classes including additive manufacturing, cybersecurity, data collection and machine learning. Some customers tell us that it is easier to track completion of courses for regulatory bodies when offered this way. Our courses go well beyond Smart Manufacturing topics. Developed with manufacturing experts, we offer interactive and engaging online courses covering technical and non-technical subjects from machining to inspection to employability skills. With training resources such as short-term online classes, nationally recognized certifications, and assessments, we help companies build strong teams. We frequently receive positive feedback about the flexibility of accessing the material wherever employees are, whenever they have free time.

This Spring, we are launching Tooling U-SME Virtual Reality (VR) Labs. The VR Labs, used with an Oculus VR Headset or on a computer, are an efficient way to safely apply your knowledge, contributing to confidence and proficiency on the shop floor. This immersive experience allows for repeated practice after students or employees complete their eLearning curriculum and before training on real equipment. It’s a training approach that improves safety, increases productivity, and reduces costs. It’s great for hiring too. The “gaming” aspect especially appeals to younger generations, helping generate excitement about a career in manufacturing. While we don’t suggest that online learning will replace in-person instruction, on-the-job training (OJT) or hybrid training programs are here to stay.

Investing in workforce development and creating exciting career pathways empower people to build and innovate. Well-trained employees can identify operational improvements, new product ideas and breakthrough enterprise-wide solutions to build a competitive advantage for manufacturers. We need to ensure that progress on workforce development starts now so that we aren’t left at the end of the next decade wondering how nothing has changed. While a significant intervention around this topic is needed, consistent, small improvements can add up to effective recruitment, retention and training practices that drive the growth and success of your company. For more information, visit www.toolingu.com

ABOUT THE AUTHOR:

Attract & Retain In the end, whether for new hires or incumbent employees, engagement and retention come from creating a culture of learning and providing training opportunities tied to a clear career path. Best practices before and after the first day include: » Strong onboarding and buddy system » Career pathways that align with pay » Regular feedback, both formal and informal

Modex 8in x 4.75in Ad Amanda.pdf

13/02/2020

Jeannine Kunz is the vice president of Tooling U-SME. For more than 90 years, Tooling U-SME has worked with manufacturers, educators, government, and other organizations to build training programs and support workforce learning initiatives

17:33

SAFETY | STORAGE | EFFICIENCY 877-COMBI-56

COMBILIFT.COM

CMY

Save up to 100% more storage

Before you invest in upgrading the infrastructure of your warehouse find out how Combilift could dramatically increase storage, improve productivity and enhance safety.

Our warehouse design consultancy service is FREE and without obligation. When combined with our material handling products we can deliver possible space savings of up to 100%. So contact us today to arrange a site survey!

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 29

New Technology

Highly efficient, Yaskawa’s four- and five-axis palletizing robots efficiently handle varying-sized loads for increased production output.

Lost in Logistics No More! Scalable robotic automation helps navigate the way to productivity

By: Chris Ruelle, Key Account Manager at Yaskawa America Inc. – Motoman Robotics Division

necessity for future growth, supply chain resilience is more important than ever. Large-scale disruption during the global pandemic exposed production bottlenecks, indicating key areas for both process and equipment improvement. Add in the on-going complexity of consumer specifications, and companies continue to scramble to achieve more with less, meeting stringent requirements. From factory space restraints to skilled labor shortages, hard realities permeate the industrial landscape. As a result, company leaders continue to look for proven solutions to bolster operational efficiency and product quality to effectively fill orders. A growing asset – especially for e-commerce fulfillment in both manufacturing and distribution spaces – robot utilization is now the advanced technology “go to” for quickly adapting to surge in demand for on-time delivery. Nearly 50% of supply chain leaders admit to accelerating investment in advanced technology, including robotic automaton1. Fast-tracking the growing digital supply chain, this adoption facilitates more responsive and forward-looking operations. Highly influential to factories and warehouses in recent months, is the use of scalable robotic automation. With almost 80% of distribution centers operating manually with a limited labor pool2, the successful integration of flexible

30 | IMD

MARCH 2022

easy-to-use robots has the potential to provide companies with an attractive return on investment (ROI). Especially true for material handling applications, the robot segment for the Automated Material Handling Equipment Market continues to be a front-runner in market size for installed automation tools3, and companies that fail to take advantage of advanced robotic technology run the risk of falling behind in today’s high-mix, low-production industrial landscape.

Value Added Tasks To better facilitate the goods to consumer process, savvy company leaders are targeting prime areas that have the potential to benefit from highly reliable robots, creating more dynamic fulfillment environments. Fixed automation layouts with task-specific machinery are giving way to flexible automation options with more adaptive technologies. Fast, compact industrial robots are transforming many primary and secondary requirements, while higher payload extended-reach models are optimizing end-of-line tasks. Designed to work safely with or alongside humans, highly portable easy-to-program collaborative robots are also facilitating extremely productive workspaces, enabling fast deployment and redeployment on demand.

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

Top applications include: Parcel Sortation Perhaps the greatest need for robotic automation, where the supply chain is concerned, is for parcel sortation. Manually identifying and processing items such as boxes, envelopes and polybags (typically from a conveyor) for sorting or further diverting to a specific destination is tedious and injury prone work. This can lead to sorting inaccuracy. By transferring manual operations for pick and place tasks to automated areas that can accurately manage the high volume of parcels required, companies can Adaptable easy-to-use robots are fast-tracking parcel sortation for greater product throughput. save valuable time and resources. Image courtesy of Dorabot. Whether being implemented for bulk receiving of items, converting bulk flow of items into Mixed-Load Palletizing singulated flow, or sorting and redirecting parcels according Often an ideal place to start for robotic implementation in to a destination, extremely accurate and agile robots can distribution and logistics settings, this extremely repetitive make a transformative difference for this highly repetitive application accommodates demand-driven loads. Capable task. Innovative companies often blend intelligent 3D vision of handling and stacking multiple Stock Keeping Unites and artificial intelligence (AI) with robots to create advanced (SKUs) onto a pallet, robotic mixed-load palletizing, sortation solutions, solving unique order fulfillment tasks in maximizes pallet density for increased capacity. While the real time with minimal human intervention. palletizing of homogenous layers of any single SKU is quite

Drill. Tap. Assemble. Form your own inserts on standard shop equipment.

Advantages & Benefits • • • • • • •

Cost savings (up to 90%) • High load threads - stronger joints • High process reliability • Faster production cycles No special machinery required Small investment Increased material thickness

Long tool life Chipless process Innovative technology suitable for steel, stainless steel, copper, brass, and aluminum

773-290-1040 | info@formdrill-usa.com

www.formdrill-usa.com

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 31

common, the palletizing of mixed SKUs within a layer – where dissimilar packages such as boxes, bottles, polybags and more are used – is quickly gaining traction for manufacturers and distributers of all sizes. Enhancements in advanced technology enable the application of robotic vision, machine learning and AI with software intelligence, making robotic arms more adaptable and perceptive for palletizing tasks. This utilization of intuitive tools and pallet pattern generation software makes palletizing easier, calculating the optimum number of unit loads (or pallets) that can be created from the pick sequence of an order fulfillment. Product characteristics drive the pallet build algorithms which correlate data such as sequence and orientation of the packages in relation to the robot and gripper coordinates. Highly intelligent, the software helps place large, heavy products on the bottom of pallets, while small, lightweight objects are placed on top of loads. In short, user-friendly software creates more flexible palletizing systems that can improve worker safety, order accuracy, product quality and throughput capacity for adapting to dynamic industry change. Overall handling and shipping costs, including carrying costs per SKU, are also Robots help improve the operational effectiveness of warehouses and distribution centers by typically lowered. While no single mixed-load reducing injuries to workers, reducing product damage, and reducing loss due to theft. palletizing system is a one-size-fits-all solution, implementing one can provide the process speed resource planning (ERP), and decision makers are better and reliability that many operations are currently seeking, even positioned to navigate supply chain struggles. for harsh working environments.

Motion Control Truck Loading / Unloading Whether for delivery or facility-to-facility distribution, truck loading and unloading thrives on organization. Once a chaotic process, the transfer of packages to and from a vehicle (or vice versa) is easily facilitated with the appropriate robot and peripheral tools. Because of the variety in package sizes and types, it is extremely important for decision makers to work with an experienced robot supplier to plan the system accordingly. A long-reach robot capable of reaching the entire volume inside the truck to retrieve or place packages is ideal. Proper end-of-arm tooling (EOAT), a capable vision and processing system, as well as a suitable conveyor system can quickly, accurately and ergonomically handle packages. Highly important to facilitating the loading and unloading process, robotic automation’s ability to stack sorted packages in an organized Tetris-style manner for transport is a competitive edge game-changer.

Supply Chain Success The shift from mostly manual operations toward smart robotic automation solutions simplifies processes, providing transformative benefits and productivity gains. Add in the use of standard programming environments and enterprise

32 | IMD

MARCH 2022

Eliminating the need for proprietary language, motion control platforms or Programmable Logic Controller (PLC) solutions, provide a standard programming environment to ease robot setup through simplified communications. Tools like the MLX300 controller software, for example, increase production through Singular Control™ of multiple mechanisms including industrial robots, servo systems and variable frequency drives. This offers a user-friendly approach to automation that empowers companies to tackle dynamic packaging and distribution requirements.

Asset Management The use of enterprise resource planning (ERP) or integrated asset management for more informed decision making throughout the value creation chain helps decision makers navigate supply chain struggles. Proven edge server solutions that use a leading OPC-UA interface, like Yaskawa Cockpit™, support multiple brand devices and collect information in real time to enable data-driven optimized planning. The ability to see what is occurring at any point along the value creation chain is extremely advantageous to unifying critical business functions. Aspects such as finance, inventory, manufacturing and order fulfillment can be easily managed, translating to greater productivity and cost savings.

Robots and their peripherals are strategically designed to integrate with existing machinery and systems bolstering confidence in decision makers that are fearful of drastic equipment overhauls. Companies ready to move forward should follow a clear strategic plan and work with an experienced robot supplier or integrator. Not only can this relationship serve as a guide for selecting and integrating the proper robotic workcell, but also, it provides a line of communication with an expert where robot training and maintenance are concerned, positioning companies for future growth and a stronger ROI. ABOUT YASKAWA MOTOMAN Founded in 1989, the Motoman Robotics Division of Yaskawa America, Inc. is a leading robotics company in the Americas. With over 500,000 Motoman® robots installed globally, Yaskawa provides automation products and solutions for virtually every industry and robotic application; including arc welding, assembly, coating, dispensing, material handling, material cutting, material removal, packaging, palletizing, spot welding and clinical laboratory specimen processing. For more information, please visit our website at www.motoman. com or call 937.847.6200.

The industry’s first IP67-rated collaborative robot, the six-axis Yaskawa HC20 robot with 1,900 mm maximum reach is capable of loading and unloading a 40" x 48" pallet without the presence of an elevator.

SOURCES: 1 Innovation Driven Resilience, MHI, 2021 2 The Business Case for Robotics in Distribution Centers, Honeywell Intelligrated, 2020 3 Automated Material Handling Equipment Market Worth, MarketsAndMarkets, 2021

E B R AT I

N G

TRIMS AND SEALS

50 YEARS

AND STILL GROWING!

YEARS

NEW FACILITY COMING SPRING 2022 ELKHART, INDIANA

CALL US TODAY!

800-663-9507 WWW.TRIMLOK.COM INFO@TRIMLOK.COM 6855 HERMOSA CIRCLE BUENA PARK, CA 90260

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 33

Process

100%

INSPECTION

High-Speed Non-Destructive Ultrasonic Scanning Identifies Minute Defects in Specialty Metals and Alloys

igh purity metals and alloys such as aluminum, zinc, cobalt, copper, titanium, zirconium, molybdenum, magnesium, and stainless steel are the backbone of many industries, from electronics to aerospace, and medical devices. Due to the critical nature of many of the components made from these materials, high purity alloys should be highly consistent, with extremely low levels of impurities and contaminations. This is driving non-destructive inspection using Scanning Acoustic Microscopy (SAM) to identify small inclusions and other defects as small as 50-microns. Scanning Acoustic Microscopy (SAM) is widely accepted in the semiconductor industry as a failure analysis and reliability detection metrology technology. Now the same technology, with variations in instrumentation and adaption for different use cases, is being applied to high purity metals and alloys. The challenge, however, is performing 100% inspection at sufficient throughput speeds to remove materials with defects that do not meet strict quality requirements. As with other inspection systems, increasing scanning speed traditionally meant sacrificing scanning image resolution. Fortunately, recent advancements in SAM technology have significantly improved throughput speeds and defect detectability. “While a conventional 5 MHz sensor could take up to 45 minutes to inspect an 8–10-inch square or disc alloy, an advanced phased array with 64-128 sensors and innovative software to render the images reduces inspection time to five minutes with more granular detection of small impurities or defects,” says Hari Polu, President of OKOS,

34 | IMD

MARCH 2022

a Virginia-based manufacturer of SAM and industrial ultrasonic non-destructive (NDT) systems. OKOS is a wholly owned subsidiary of PVA TePla AG, Germany and offers both manual and automated inspection systems for flat panels, thin plates, circular discs, sputtering targets, and special alloys. By dramatically increasing inspection speed, Polu says the specialty metals industry is no longer limited to selective

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

sample testing during In-Process Quality Control. Although SAM has long been utilized for this type of inspection, the testing involved a handheld unit or a multi-point inspection. Now it is more feasible to conduct 100% inspection of the entire surface/interface. In addition, these advances also facilitate the detection of not just gross defects, but much smaller defects, to drive highly consistent, high yield products. “Advanced, phased array SAM systems make it possible for specialty metals divisions to move to a higher level of failure analysis because of the level of detection and precision involved,” says Polu. “In the past, detecting a 500-micron defect was the goal; now it is a 50-micron defect. And with high purity metals, they want to inspect every item, not just a few samples.”

Scanning Acoustic Microscopy SAM is a non-invasive and non-destructive ultrasonic testing method. The testing is already the industry standard for 100% inspection of semiconductor components to identify

defects such as voids, cracks, and the delamination of different layers within microelectronic devices. Now, the same rigor of failure analysis and quality testing is being applied to specialty metals and alloys to detect subsurface flaws, dis-bonds, cracks, and other irregularities. Scanning acoustic microscopy works by directing focused sound from a transducer at a small point on a target

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 35

object. The sound hitting the object is either scattered, absorbed, reflected, or transmitted. By detecting the direction of scattered pulses as well as the “time of flight,” the presence of a boundary or object can be determined as well as its distance. To produce an image, samples are scanned point by point and line by line. Scanning modes range from single layer views to tray scans and cross-sections. Multi-layer scans can include up to 50 independent layers. Depthspecific information can be extracted and applied to create two- and three-dimensional images without the need for time-consuming tomographic scan procedures and more costly X-rays. The images are then analyzed to detect and characterize flaws such as cracks, inclusions, and voids. When high throughput is required for 100% inspection, ultra-fast single or dual gantry scanning systems are utilized along with 128 sensors for phased array scanning. Multiple transducers can also be used to simultaneously scan for higher throughput. “In tests with a Fortune 500 multinational company on a sample of this aluminum and steel, the equipment was able to scan the material in three minutes. Before, it was taking them 40 minutes to do one part,” says Polu.

36 | IMD

MARCH 2022

OKOS Software As important as the physical and mechanical aspects of conducting a scan, the software is critical to improving the resolution and analyzing the information to produce detailed scans. Multi-axis scan options enable A, B, and C-scans, contour following, off-line analysis, and virtual rescanning for composites, metals, and alloys, which result in highly accurate internal and external inspection for defects and thickness measurement via the inspection software.

“OKOS decided early on to deliver a software-driven, ecosystem-based solution,” said Polu. The company’s ODIS Acoustic Microscopy software supports a wide range of transducer frequencies from 2.25 to 230 MHz. Polu estimates that the company’s software-driven model enables them to drive down the costs of SAM testing while delivering the higher quality of inspection results at faster speeds. “In the electronics, aerospace, medical device, and other industries, there is an increasing demand for inspection equipment that can perform non-destructive imaging and materials analysis,” says Polu. “With more sensors and advanced software to interpret the information at very high resolutions, specialty

metals manufacturers can inspect 100% of the materials at a level one to two orders of magnitude better to discover flaws that were previously undetected.” For more information, contact OKOS at info@okos.com or visit www.okos.com. OKOS is a wholly owned subsidiary of PVA TePla AG, Germany

C-FRAME PRESSES MADE IN THE USA!

• 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.

WE CAN BUILD A CUSTOM MACHINE FOR YOU!

HYDRAULIC MACHINES OF IOWA

A Division of Betenbender Mfg. Inc

Phone: 319.435.2378 | Fax: 319.435.2262

www.betenbender.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 37

Industry Insight

10 Inventory Must Do’s for Small to Medium-Sized Manufacturers By: Adam Grabowski, Director of Marketing, Global Shop Solutions

ash is king for manufacturers – from the owner down to the machine operators. If you visit any manufacturer, you will see most have a keen eye on how everything is being used. Machines are generally only running if they are making parts; employees are typically only working if orders are coming in; and scrap is examined carefully to determine “How did this happen? How can we prevent it from happening again? What else can we do with this?” Even the best manufacturing owners make mistakes. But rarely, do they make the same mistake twice. If you ask them what some of their biggest mistakes have been, they are often tied to how their inventory was managed. Meaning, that was in the past and today they are doing something different. What is different? After speaking with many manufacturing owners and many subject matter experts, the “different” is their business

38 | IMD

MARCH 2022

is choosing to live and die by the following 10 inventory must do’s with the help of ERP software.

1. Clear Out the Inventory Garbage What does this mean? It means you must process your inventory correctly and consistently with no exceptions. Your inventory processes should be documented, and employees trained, retrained, and trained some more; and you should have absolute consistency in your product lines, units of measure, etc. Documenting your process also means knowing explicitly who owns what including inventory master, inventory costing and inventory quantity. Everyone should know what they are doing, when, why, and the consequences of it being done incorrectly. Don’t let the fox guard the henhouse. The employee responsible for transaction processing cannot have access to inventory adjustments. A few hours spent training employees will save you money and heartache (and maybe

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

even a lost customer) when you try to make a part with inventory you don’t have. Clear the garbage out of your inventory process, and you will be left with a much better result.

2. Regulate Your Inventory Counts Physical inventory or cycle counts should always be performed on a regular basis and produce accurate numbers. By implementing regular inventory counts, this allows you to consistently ensure inventory accuracy throughout the year. We’ve found that our customers complete this in one of two ways. The first being the cycle count daily or weekly, which means they count parts based on usage or dollar amount to verify their inventory is correct. If their numbers are getting adjusted, that means their inventory is off, and they must figure out what inventory transactions are causing the issue. The second way our customers regulate inventory is by doing physical inventory, which calls for shutting down the shop floor and counting the inventory one weekend a year, sometimes two. To learn more about this, download subject matter expert Brady Steven’s whitepaper titled “How to Achieve Perfect Physical Inventory in 10 Easy Steps.” It is a great, superfast read that is likely to save you thousands of dollars a year.

Listen to the vendor’s sales pitch and what they have to offer as far as pricing and quality rating. You may be surprised by what they have to offer. If you stick with the same vendor year after year, you may not receive the best bang for your buck. Prices slowly and steadily creep up, and your discounts suddenly vanish. Evaluate cost regularly and do not ignore savings on buying items in bulk when appropriate. This can be an opportunity for blanket orders to come into play with your vendors, and you will

3. Evaluate Unused Inventory Just like clutter in your home, obsolete inventory or low turn inventory should be evaluated on a regular basis, not just once a year. Inventory takes up space and space is money. If something is taking up space and not moving, that is taking away an opportunity for something that you could be selling and bringing in more revenue for your company.

4. Know Your Business’ Trends Keeping your inventory labeled is an important step in controlling your inventory between physical inventories. Be “hip” with your business. Reorder, lead time, and order quantity should be reasonably accurate and should be evaluated on a regular basis (and again, this doesn’t mean once a year). You know your business better than anyone and knowing when spikes occur throughout the year allows you to better plan on seasonal changes in your inventory. If your business is seasonal, you may need to adjust your min/max quantities throughout the year as well. A great way to evaluate this data is to be using Key Performance Indicators for your business.

5. Research Your Vendor’s Competition Your vendors win when you get lazy. So, it’s okay to pick-up those pesky sales calls every once in a while. INDUSTRIAL MACHINERY DIGEST.COM

IMD | 39

receive a discount by planning ahead. But remember, this requires you to know your business trends and when those seasonal spikes occur.

6. Automate As Much As Possible If job costing is a full-time job, then you probably have inventory issues. By automating with our Job Costing Accounting application, you can spend less time worrying

quality matters. every time.

about what your finished goods cost and more time on creating a quality product. Good job costing leads to accurate inventory cost and quantity, providing you with an opportunity to automate part or all of this process ever year.

7. Record Your Inventory Flow You are what you eat. As inventory is consumed or shipped, it needs to be recorded. Some of our customers manage this process with one person, a team of people, or they let their machinist move the parts. It’s entirely up to you, and you can decide who manages that process based on how skilled your employees are and the type of material. The inventory process is as follows: 1. Issue Material to Work Order 2. Bin-to-Bin Transfer 3. PO Receipts 4. WIP (Work in Progress) to Finished Goods 5. Location Transfers You also have the option of backflushing and Auto WIP should you choose. If you make it to the last step and you have 10 good parts, then 10 parts are WIPed into inventory (finished goods). Spend a few minutes every time and record inventory flow immediately and you’ll save yourself hours in the long run.

8. Listen to Your Business With ERP

PRO GRADE

HOSE, CORD, & CABLE

REELS

SOLUTIONS FOR:

TOLL FREE | 800.269.7335

www.coxreels.com

40 | IMD

MARCH 2022

Hearing is the act of perceiving sound, but listening is something you choose to do. Move beyond “hearing” with your fully integrated ERP system with MRP functionality and “listen.” Manufacturers that are using an ERP system correctly are faster, smarter, and more profitable than those who don’t. It isn’t a question; it is truth, and we have 150 case studies to prove it. Listen to your business by viewing and analyzing the data your ERP system provides to see trends, view roadblocks and make better business decisions. Utilizing

your Business Intelligence application, KPI application, and Dashboards, you can see inventory detail in real-time and allow you to listen to your inventory.

9. Correct Employee Mistakes Immediately In manufacturing, loose lips don’t sink ships. They save them. Employee attitude and participation is the icing on the cake, and if an employee or machine isn’t doing something correctly, don’t let the ship sink. For example, if you see Jane Doe routinely recording inventory, but she always misses a few parts, your inventory counts will continuously be off and you will be spending more money purchasing inventory you don’t need. Speak to a manager or superior and let them know your concerns about the issues you’re witnessing. Speak up and refer to Must Do #1. Honesty is the best policy when it comes to business, especially with money being involved. By addressing inventory mistakes early on, you reduce the risk of losing money, inventory and production time.

10. Always Ask Questions Don’t guess how to do it – ask someone. There are unlimited resources available to you at Global Shop Solutions. If you’re a customer, connect with your Customer Success Manager, schedule a Virtual Training with a member of our Consulting department, or attend one of our 80+ training events a year. If you’re in the market for ERP software, see the software for yourself. We can connect you to some great customers if you have any questions. Don’t let the fear of asking a “dumb” question keep you from managing your inventory the correct way and making money for your business. To learn more about the 10 inventory must do’s for small- to medium-sized manufacturers, call 1.800.364.5958 or visit www. globalshopsolutions.com

ABOUT THE AUTHOR: Adam Grabowski is the Director of Marketing at Global Shop Solutions. He is responsible for translating the company’s business objectives into successful brand, marketing, and communication strategies to drive awareness, revenue, and loyalty.

MAGNETIC DRILL STAND EASY-TO-USE

KANETEC MAGBORE DRILL GUIDES Offer sure, positive, firm footing!

Model KCD-MN1 • • • •

COMPACT LIGHTWEIGHT HOLDS POSITIVELY MAGNETICALLY ATTRACTS OR RELEASES • WEIGHS UNDER 12 LBS.

(Drill not included)

For Round Pipe in Magnetic or Chain

Models now available for round pipe in two styles: Magnetic for ferrous steel or Chain grip for PVC, aluminum, and other non-ferrous materials.

630-860-1545

Visit: KANETEC.COM KANETEC@KANETEC.COM

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 41

Product Showcase

PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers. Cracking the Code: Connecting IMD Readers with More Information To learn more about each product, scan the included Quick Response (QR) code with your mobile device. These special barcodes have been designed to allow our readers to quickly and easily discover more information available on IndustrialMachineryDigest.com. WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

Custom Machine and Tool Co., Inc. Offers 72-hour GUARANTEED SHIPPING Pulley Stocks Precise. Reliable. Trusted. Made in the USA. Since the establishment of Custom Machine and Tool Co., Inc. (CMT) over 56 years ago, they have enjoyed exponential growth and success. Robert Bennett, President of Custom Machine and Tool Co., Inc. believes that a strong economy, the ingenuity, and inventiveness of their employees, the ability to control processes, as well as source materials and help customers with fair pricing and quick deliveries are just some of the reasons why. Bringing it to the next level and beyond! When Robert Bennett took over the reins of Custom Machine and Tool Co., Inc. (CMT) from his father, Edward, in 1980, his goal was just that. He was going to “Bring it to the next level and beyond!” His father had begun manufacturing his screw machine products in the basement of his Scituate, Massachusetts home. Edward quickly gained a reputation for his dedication to precision and quality…endowments that would serve as a template for Robert’s future endeavors.

BLM GROUP Expands ELECT40 Tube Bender Capability with Compact Head BLM GROUP has announced the availability of its ELECT40 all-electric tube bender with an elongated, compact head capable of executing shapes previously not possible with singledirection bending machines. The new bending head…

42 | IMD

MARCH 2022

Doosan Robotics’ Collaborative Robots Marks Annual Sales Of Over 1,000 Units, Breaking Through Domestic Records Doosan Robotics announced it has become South Korea’s first to achieve an annual sales record of 1,000 units for collaborative robots (cobots). Established in…

Exact Metrology Offers RS6 Laser Scanner Exact Metrology: A Division of In-Place Machining Company and a comprehensive metrology service provider, recently released the Hexagon RS6 laser scanner, designed for high-speed and accuracy scanning. It scans up to 1.2 million points/sec with a scan rate of 300 Hz.…

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

NEW PRODUCT: Digital Static Meter for Measuring and Identifying Sources of Static EXAIR’s Model 7905 Digital Static Meter provides an easy-to-use, handheld tool for measuring and identifying sources of static in your processes. Static electricity can wreak havoc in manufacturing processes affecting product quality…

New PlateSaver Technology from Hypertherm Helps Customers Maximize Parts and Profit Per Plate

90 Degree Adapter from Guill Guill Tool, a growing supplier of components to the global aerospace industry, today announced the production of a 90 degree adapter. The adapter is made of 304 stainless steel and measures 1.498” X 1.825” X 3.188” (38.049mm x 46.355mm x 80.975mm) overall length.

Hyster Wins Award For High-Capacity Electric Forklift

Rust Proof Chemical Resistant Canopy Hoods Canopy Hoods are designed to collect and exhaust corrosive vapors, heat, steam and odors. They are available in 36”, 48”, 72” & 96” widths, in Wall or Island models. Canopy hoods are available in either molded chemical resistant flame-retardant one-piece composite resin or…

MC Machinery Offering Demos of New ASTES4 High Speed ADVANCED Modular Sorting System with Integrated Tool Changer

Hypertherm, a U.S. based manufacturer of industrial cutting systems and software today introduced PlateSaver™, a new SureCut™ technology that automatically maximizes the number of parts on…

The Hyster® J155-190XNL, a high-capacity lift truck series powered by an integrated lithium-ion battery pack, is a winner of the prestigious 2021 GOOD DESIGN Award. The truck is the first sit-down counterbalanced lift truck in the 15,500-to-19,000pound load capacity range…

New and Improved Solutions from Niagara Cutter for Aluminium Machining

United Precision Services Providing MicroStep Dome Cutting Solutions

New Tiger·tec® Gold inserts from Walter handle tough steel turning applications

Introducing the new and improved A245/345 product families from Niagara Cutter, a Seco Tools company. These tooling solutions have been redesigned to reduce power consumption and improve chip evacuation in aluminum machining applications…

United Precision Services, Inc., a leading provider of turnkey medium to large CNC machine tool solutions, is offering MicroStep’s dome-cutting technology to the North America fabrication market. The MicroStep beveling tool station allows CNC…

Walter has introduced Tiger·tec® Gold inserts, specially designed for turning operations in all steel applications including low carbon steels as well as various alloy steels. A key feature of these inserts for turning is their outstanding process reliability. This…

MC Machinery Systems is offering on-site demos of the new ASTES4 High Speed ADVANCED, a modular sorting system that can cut sort times in half, reduce labor costs, improve…

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 43

On Exhibit - MODEX

ON EXHIBIT Industrial Machinery Digest's On Exhibit features the latest news and press releases from companies exhibiting at the leading trade shows across North America. WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com

MARCH 28-31, 2022 Atlanta's Georgia World Congress Center When the largest manufacturing and supply chain trade event of 2022, MODEX, returns to Atlanta on March 28 it will include over 900 exhibits from leading solution providers and a comprehensive Educational Conference of over 150 sessions focusing on best-inclass solutions for manufacturing and supply chain operations. MODEX 2022 exhibits will represent all segments of the material handling, logistics and transportation industry, from traditional, manual equipment to computerized, automated systems and smart, connected supply chain technologies.

www.modexshow.com

BOOTH: B5011

BOOTH: B7747

Highlights will include the new SIMATIC MICRO-DRIVE, designed for ultra-low-voltage applications, in a demonstration of an automated guided vehicle (AGV). Also featured will be the new SINAMICS G115D, a recently released distributed drive system, specifically designed for conveyor applications. Displays in the Siemens…

Holzkurier, the leading Austrian publication for the timber sector, has named Combilift as its Timber Trade Supplier of the Year for 2022. The company’s continual product development, its impressive growth in the Austrian market, and a policy of always putting the customer center stage were just some of the reasons cited by the…

BOOTH: B5227

BOOTH: B6855

TwinCAT/BSD Hypervisor, a powerful new feature of the TwinCAT/BSD operating system from Beckhoff, enables simultaneous execution of virtual machines and TwinCAT real-time applications on an Industrial PC (IPC). Optimized hypervisor integration in TwinCAT/BSD, plus matching configurations of Beckhoff hardware…

FANUC America has introduced the new M-1000iA robot capable of handling very heavy products including automotive components, construction materials and battery packs for electric vehicles. The M-1000iA’s serial-link construction gives the robot a wider range of motion in every direction. It can extend its arm upright or rotate…

Siemens Offers Turnkey Logistic Solutions for Material Handling Processes at MODEX 2022

TwinCAT/BSD Hypervisor Provides Efficient Engineering and Execution of Virtual Machines

44 | IMD

MARCH 2022

Combilift is named Timber Trade Supplier of the Year by Leading Austrian Timber Publication

FANUC Introduces New M-1000iA Robot Designed to Handle Heavy Products

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

BOOTH: B2926

BOOTH: C7685

The Winona, Minnesotabased manufacturer has targeted the products at applications where there are gas or dust particles that could create a spark. Typical markets include oil and gas, wastewater, paper, mining, and others where an explosive atmosphere exists. The products are launched as a complete capacity range—0.5 ton, 1 ton, 2 ton, 3 ton, 5 ton, 10 ton—that covers most likely applications.…

In Seegrid’s booth, MODEX attendees will see firsthand how the company’s next-generation autonomy technology, Seegrid IQ, offers enhanced perception and humanlike awareness, enabling AMRs to reliably and safely transport goods across busy factories and dynamic warehouses. Recently named the #1 Autonomous Mobile Robot Provider in the US by Interact Analysis…

OZ Lifting Launches Spark Resistant Range

Seegrid to Unveil New Autonomous Lift Truck at MODEX 2022

BOOTH: B2805

BOOTH: C4093

Universal Robots, the Danish producer of collaborative robots, has reported record annual revenue of USD 311M, 41% up on 2020 and 23% up on pre- pandemic results in 2019. The company’s President, Kim Povlsen said: “Universal Robots has had a great year. In a company like ours, which manufactures…

Featuring multiple improvements and optimization, Yaskawa’s Smart Pendant software version 2.1 extends capability for the highly intuitive and easy-to-use Smart Pendant. Building on prior software updates, the highly efficient Smart Pendant v2.1 is well-suited for quick robotic implementation of basic assembly…

Universal Robots Reports Record Annual Revenue of Over $300M

Smart Pendant Software Version 2.1 Expands Ease of Use and Controller Performance

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 INDUSTRIAL MACHINERY DIGEST.COM

IMD | 45

SELECT

EQUIPMENT

Industrial Electrical Sales MCC BUCKETS & MOTOR CONTROL CENTERS CUSTOM BUILT MCC BUCKETS • LARGEST INVENTORY IN THE MIDWEST!

WE CAN RETROFIT ANY MAKE AND MODEL OF MCC BUCKET WITH ALL NEW COMPONENTS INCLUDING VFD’S! SOFT STARTERS NEMA & IEC STARTERS

888-459-5191 • SALES@SELECTEQUIPMENT.NET

SELECTEQUIPMENT.NET

46 | IMD

MARCH 2022

Stay Connected

YOUR COMPLETE AUCTION RESOURCE With our user-friendly website, users can easily find the type of auction they are looking for, regardless of size or location. The site has the latest technology to make it simple for users to engage with an auction of interest.

Denver Breaker & Supply Mention SBSDA2022 for a 10% Discount!

YES...We Have That! Subscribe now to receive FREE news on upcoming auctions!

IMDauctions-Q-092018.indd 1

8/23/18 11:31 AM

One of the Nation’s Largest Inventory of New, Obsolete, Inspected & Tested Electrical Equipment!

Circuit Breakers • Controls Panel Mount Switches Motor Bus Duct Plugs • Transformers Starters and More! Providing Same Day, Next Day Air Shipments for Emergency Needs!

WE ALSO BUY YOUR USED EQUIPMENT…

CALL US TODAY!

855-4UR-BRKR www.DenverBreaker.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 47

2022 S E AT T L E ORLANDO CLEVELAND S A LT L A K E C I T Y DETROIT MORE TBA

FREE

800.829.7467 ADMISSION ATTENDEE PARKING SEMINARS

Standard-Direct.us

3D PRINTING DESIGN ENGINEERING PROTOTYPING MACHINING CUTTING GRINDING

FORMING FABRICATING RUBBER PLASTICS COMPONENTS CASTINGS MOLDS

TOOLS DIES PATTERNS FINISHING ASSEMBLY FIXTURES ELECTRONICS

...AND MUCH MUCH MORE.

See Manufacturing’s Latest Cutting-Edge Technologies at ANY of Our Upcoming Shows Spring 2022

Seattle, WA ................................................................ February 21-22 Orlando, FL .......................................................................April 13-14 Cleveland, OH ....................................................................... May 3-4

Fall 2022

Salt Lake City, UT ............................................................ October 5-6 Detroit, MI.................................................................November 15-16

More Shows TBA

STRUCTURAL STEEL CO., INC.

ESSEX PROVIDES Pre-Engineered Buildings Built to Withstand the Rugged Northeast Winters. Commercial, Industrial, and Agricultural Buildings Built to Satisfy Your Building Needs. Steel Structure, Sub-Structure, and Sheeting

Call For A Quote On Your Next Project STRUCTURAL STEEL CO., INC.

800-323-7739 www.EssexStructuralSteel.com

607-753-9384 • FAX: 607-753-6272 • 607 Route 13, Cortland, NY 13045

48 | IMD

MARCH 2022

www.enmco.com classifieds

www.enmco.com $24.00

40% off list price www.enmco.com $24.00 (Limited time

40% off listpricing) price promotional $24.00 (Limited time 5 other styles available 40% off list price

promotional pricing) (Limited time promotional pricing) 5 other styles available 5 other styles available

........... Visit Online Today!............

OIL MIST & SMOKE IN YOUR SHOP?

MachineShopWeb.com

www.mistcollectors.com Tel: 1-800-645-4174

........... Visit Online Today!............

Electronics Customer Pre-settable LCD Timer

AmericanMachineShop.com

Series TB45

ENM’s Series TB45 is a pre-settable AC/DC hour

meter. It features a 6 digit LCD with self-powered Electronics Customer Pre-settable LCD Timer CMOS circuitry.The unit is powered by an Electronics Customer Pre-settable internal lithium battery. LCD Timer

Series TB45

ENM’s Series TB45 is a pre-settable AC/DC hour meter. ENM’s TB45with is a pre-settable AC/DC hourcircuitry. It features a 6 Series digit LCD self-powered CMOS features a by 6 digit LCD withlithium self-powered Themeter. unit isIt powered an internal battery. CMOS circuitry.The unit is powered by an

Need Work Benches Need Need Work Work Benches Benches Need Work Benches

........... Visit Online Today!............ BoothLocation.com

internal lithium battery.

MADE IN THE U.S.A e-mail: customerservice@enmco.com

TOLL FREE 888-372-0465

???

In Stock-Factory Direct InIn Stock-Factory Stock-Factory Direct In Stock-FactoryDirect Direct

workbenchmarket.com workbenchmarket.com

workbenchmarket.com

MADE IN THE U.S.A e-mail: customerservice@enmco.com

TOLL FREE 888-372-0465

Check it out!

F U R N A C E

C O , I N C

Dauctions-8th-022019.indd 1

1/30/19 8:06 A

Only $5000 $5000 Only

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 49

Advertiser Index Accudyne Products USA — www.ezpullerusa.com .................................................................... IBC Actek Manufacturing and Engineering Inc. — www.actekmfg.com ........................................ BC AmCon Design & Contract Manufacturing Expo — www.amconshows.com .......................48 ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ........................................ 5 Betenbender Manufacturing, Inc — www.betenbender.com .....................................................17 Carell Corporation — www.carellcorp.com ................................................................................... 13

SERVING AMERICAN MANUFACTURERS FOR OVER

36 YEARS

Clamprite — www.clamprite.com .................................................................................................... 35 Combilift, USA — www.combilift.com ............................................................................................29 Cosen Saws, USA — www.cosensaws.com ................................................................................... 27 COXREELS — www.COXREELS.com ................................................................................................40 Denver Breaker & Supply — www.denverbreaker.com ............................................................... 47 Design-2-Part Shows — www.d2p.com .........................................................................................39 Dynabrade, Inc. — www.dynabrade.com ......................................................................................... 3 Eagle Bending Machines — www.eaglebendingmachines.com ................................................ 13 ENM Co — www.enmco.com ...........................................................................................................49 Essex Structural Steel Co. — www.essexstructuralsteel.com .....................................................48 Formdrill USA Inc. — www.formdrill-usa.com .............................................................................. 31 Fortville Feeders, Inc. — www.fortvillefeeders.com .....................................................................45 H&K Equipment, Inc. — www.hkequipment.com ......................................................................... 47 HMI div of Betenbender Manufacturing — www.betenbender.com ........................................ 37 Hypneumat Inc. — www.hypneumat.com ....................................................................................... 7 IMDauctions.com — www.imdauctions.com ......................................................................... 47, 49 IMTS | International Manufacturing Technology Show — www.imts.com ............................ IFC Industrial Magnetics, Inc. — www.magnetics.com ....................................................................... 19 Kanetec USA Corp — www.kanetec.com ....................................................................................... 41 KHK-USA — www.khkgears.us ............................................................................................................ 9 L&L Special Furnace Co., Inc. — www.llfurnace.com ..................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ........................45 Pro-Line — www.1proline.com .........................................................................................................49 Radwell International, Inc. — www.Radwell.com .........................................................................FC Royal Products — www.mistcollectors.com ..................................................................................49 Schweiss Doors — www.schweissdoors.com ...............................................................................49 Scotchman Industries, Inc. — www.scotchman.com ...................................................................11 Select Equipment Company — www.selectequipment.net .......................................................46 Standard Direct — www.Standard-Direct.com .............................................................................48 Stor-Loc — www.storloc.com .......................................................................................................... 21 Tormach — www.tormach.com ....................................................................................................... 15 Trim-Lok — www.trimlok.com .......................................................................................................... 33

50 | IMD

MARCH 2022

ARE YOU LISTED? We have launched our online, searchable directory with over 400 categories specifically designed for the industrial machinery industry. IF YOU’RE NOT LISTED, YOU’RE MISSING OUT!

PRSRT STD U.S. POSTAGE PAID BOLINGBROOK, IL PERMIT NO. 467 3590-B Hwy 31 South PMB #233 Pelham, AL 35124

IndustrialMachineryDigest.com

ACTEK HOIST RINGS

ISO 9001

0° 18 ts vo

Forged Street Plate™ Swivel Hoist Rings

Side Load Hoist Rings

Hoist Ring Kits

Swivels 360°

Drop Forged Hoist Rings

Mold Handler™ Round Base Swivel & Pivot Forged Swivel Swivel & Pivot Hoist Rings Hoist Rings Hoist Rings

200% PROOF LOAD TESTED EACH RING HAS SERIAL NUMBERS ORDERS SHIPPED SAME DAY RATED LOAD 400 LBS - 250,000 LBS

800-752-7229 | SALES@ACTEKMFG.COM | ACTEKMFG.COM

Industrial Machinery Digest - March 2022

Articles inside

ON EXHIBIT

MANUFACTURING SHOWCASE

TALKING SHOP

INDUSTRY INSIGHTS

WORKFORCE DEVELOPMENT

Safety & Maintenance

INDUSTRY NEWS

PRODUCT SHOWCASE