Industrial Machinery Digest - August 2020 by Industrial Machinery Digest

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August 2020

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Table of Contents

COLUMNS

BUSINESS 4.0 Factors Influencing Reshoring The Ramifications of Coronavirus Against a Backdrop of Tariff Uncertainty

TALKING SHOP Andrew Horner Marketing Manager, Radwell International, Inc.

20 FEATURES

MANUFACTURING SHOWCASE Stor-Loc By Russ Willcutt

WORKFORCE DEVELOPMENT

Partnering with Titans for Education Mastercam Featured in TITANS of CNC Aerospace Academy with online tutorials that provide free CAD/ CAM lessons for all

The Importance of Technology Amid the Social Distancing Era By: Rob Hruskoci, Owner & CEO, Advanced Industrial Marketing

DEPARTMENTS

NEW TECH

32 PROCESS 36

SAFETY & MAINTENANCE

What Is Advanced Machine Engineering? By: Bill Davis, Industrial Machinery and Heavy Equipment Industry Leader for Siemens Digital Industries Software

Air Curtain Industry Introduces New Exciting Uses for a Mature Product

INDUSTRY INSIGHTS

An Answer to Non-Stop Production

6 EDITORIAL DIRECTIONS 8 INDUSTRY NEWS 40 NEW NORMAL MANUFACTURING 42 PRODUCT SHOWCASE 46 SURPLUS BUYING AND SELLING 49 CLASSIFIEDS 50 ADVERTISER INDEX

ON THE COVER

32 |

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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 about Radwell in this month's Talking Shop on page 14.

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I once worked for a university that was proud of its reputation as “an institution without walls,” meaning that it encouraged relationships between the schools of medicine, engineering, business, nursing, public health, etc. This resulted in amazing research collaborations, and outcomes that couldn’t have been achieved otherwise. I think it’s the same way in manufacturing. The more each area is aware of others, the better. I remember visiting one shop that had created a schedule for spotlighting each different area within itself. It wasn’t a huge operation, so everyone could gather for an hour the last day of each month while a particular department – with beer! – gave a presentation on what happened there from start to finish, the equipment that was utilized, the challenges that were encountered and how they were overcome, and then the audience was invited to ask questions and make suggestions, including following up afterwards if anything else occurred to them late. Two things happened. First, the presenters gained from the clear-eyed perspectives of those who were not contained within their daily routine, and secondly, the presenters themselves were forced to take a closer look at what they did every day, rather than simply doing it. My impression was of a workplace that was energized and invested in the operation in its entirety, not just their one piece of the puzzle. Another company I wrote about encourages the relationship between its production line and R&D, constantly discovering fresh ideas benefiting one, the other, or both. The same can be said for OEMs that maintain strong lines of communication between outside sales and engineering, incorporating design changes customers suggest which result in a stronger relationship as well as a better product overall. Once you start thinking about how information gathered in one area can be useful in other part of your company, the momentum begins to grow, and surprising things can happen. In academia, it’s referred to as a “silo” when a discipline closes itself off from others and loses the fresh stimulus of new ideas. In manufacturing it’s mere stagnation, and a missed opportunity to capitalize on one of the simplest ways of achieving continuous improvement; by fully utilizing the assets that you already have on hand.

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Industry News Leading Manufacturer of Ovens & Furnaces Launches New Website

Grizzly Industrial, Inc. Appoints New CFO, Crystal Greear

The Grieve Corporation, experts in industrial manufacturing of ovens and furnaces with a long history of 70+ years, launched an updated website with new features and enhancements to existing capabilities. “As our company continues to grow, we look for our new website to offer the digital tools necessary to better serve our customers,” said Tony Caringella, COO. The website details Grieve’s entire selection of ovens and furnaces in a digital catalog that is easy to navigate. With hundreds of different models, customers can help narrow down the right equipment for their process by utilizing the oven finder tool by applying filters such as workspace area, operating temperature, loading method and more. Although the company offers hundreds of standard models, Grieve also has unique customization abilities to engineer the best equipment for one’s application; the site details many custom ovens and furnaces as well. Explore these features, as well as additional information on all of Grieve’s products, processes, and services at www.grievecorp.com.

Greear brings to Grizzly many years of experience in corporate and public accounting, and leadership across broad and diverse industries from hospitality to retail. She has led teams with both national and international reach and is widely regarded for her integrity, team building and in-depth knowledge of complex accounting rules. “We are excited to have Crystal join our Grizzly executive team and look forward to working with her as we seek to capitalize on the incredible growth and expansion Grizzly has experienced in the Woodworking and Metalworking industries in the US and abroad,” says Robert McCoy, President of Grizzly. Greear has lived in Bellingham, home of Grizzly headquarters, for over thirteen years and has two daughters, ages seven and nine years old. She is a CPA and holds a Masters in Accountancy from Gonzaga University. She is also on the Board of the Bellingham Technical College Foundation and was recently appointed Treasurer. “Grizzly is well positioned for growth and has many exciting initiatives,” says Greear. “And I feel really fortunate to work for a company with long-standing ties to the Bellingham community. It’s a time of incredible growth and change, which comes with challenges, and I’m excited to contribute in a positive way as the company evolves.”

Siemens and SAP Join Forces to Accelerate Industrial Transformation Siemens and SAP SE announced a new partnership that will leverage their industry expertise and bring together their complementary software solutions for product lifecycle, supply chain and asset management so their customers can deliver new innovation and collaborative business models that will accelerate industry transformation globally. Through this agreement, both SAP and Siemens will be able to complement and integrate their respective offerings in order to offer customers the first truly integrated and enhanced solutions for product lifecycle management (PLM), supply chain, service and asset management. This will enable customers to form a true digital thread integrating all virtual models and simulations of a product or asset with real-time business information, feedback and performance data over the entire lifecycle. Silos between engineering and business have existed in enterprises for decades. This new partnership will help customers to break down these siloes so manufacturers, product design teams and service managers have the information needed to quickly create and manage customer-centric product and service offerings.

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Epson Signs Olympus Controls as Distributor in the Western Regions of the U.S and Canada Epson Robots announced it signed Olympus Controls, an engineering services provider specializing in the integration of motion control, machine vision, and robotic technologies, as an official distributor of Epson Robots automation products. As factory automation projects become increasingly complex, strong collaboration between distributors and robot vendors is essential. Olympus Controls’ decades of engineering expertise and deep industry knowledge, combined with Epson Robots’ reputation for easy-to-use, proven, innovative technology, will help manufacturers reach today’s challenging factory automation objectives. Olympus’ distribution territory will cover the Western U.S states of Washington, Oregon, Idaho, Montana, Nevada, and California as well as British Columbia, Canada. The partnership with Olympus Controls involves the full lineup of award-winning Epson Robots automation products, including the extensive portfolio of SCARA and 6-Axis robots as well as the great selection of integrated options such as the IntelliFlex™ Feeding System, Vision Guide, Force Guide, and more. Epson and Olympus Controls form the perfect partnership to benefit OEMs and machine builders in health & life sciences, electronics and general assembly applications.

IMD – The Industry’s Most Extensive Industrial Publication

FANUC Recognized by General Motors as a 2019 Supplier of the Year Winner FANUC was named a GM Supplier of the Year by General Motors during a virtual ceremony honoring the recipients of the company’s 28th annual Supplier of the Year awards on Wednesday, June 24, 2020. During the event, GM recognized 116 of its best suppliers from 15 countries that have consistently exceeded GM’s expectations, created outstanding value or introduced innovations to the company. The awards ceremony was originally scheduled as a live-event to be held in March but was postponed due to the impact of the COVID-19 pandemic. The recognition is for supplier performance in the 2019 calendar year. This is the 16th time FANUC has received the award. “Our suppliers play a key role in delivering the products, services and experiences our customers deserve – and these awardwinning suppliers went above and beyond our expectations,” said Shilpan Amin, GM vice president, Global Purchasing and Supply Chain. “We also believe it’s important at this point in time to thank our entire supply base for their efforts the last few months to mitigate the impacts of COVID-19,” added Amin. “Not only have we been able to safely restart our manufacturing operations, our suppliers played a key role in assisting our initiatives to increase the supply of ventilators and personal protection equipment (PPE) for frontline health care workers to help save lives and keep communities safe.”

SKF Recognized as a Supplier of the Year by American Axle & Manufacturing SKF was recognized as a Supplier of the Year for 2019 by American Axle & Manufacturing (AAM) at AAM’s 26th Annual Supplier Day, held virtually from Detroit. “The SKF team proactively approaches AAM with new opportunities that create win/win outcomes and engages openly and competitively on new technology.” This is the second Supplier of the Year award SKF has received from AAM. “SKF and AAM have worked together to bring high-quality, innovative and competitive bearings and sealing solutions into the automotive marketplace. We deeply value our relationship with AAM and it is a great honor to be recognized as a Supplier of the Year,” said Jim Seta, President, Automotive OEM Bearings, SKF Americas.

rebuild Mazak spindles. Within a tight turnaround window, these technicians perform every stage of the repair and rebuild process, provide comprehensive and trackable spindle documentation, and conduct stringent testing of every spindle. The expansion has not only made room for additional technicians but also allows the department to boost its rebuild output to 100 spindles per month.

HEIDENHAIN Announces Opening of Expanded Western U.S. Headquarters This includes the expansion of HEIDENHAIN CORPORATION executive, sales and technical support offices, as well as demo facilities in San Jose, California. This new development includes the consolidation of HEIDENHAIN’s Fremont, CA, technical support operation into HEIDENHAIN’s expanded San Jose business center offices. “Proximity to the innovation centers and high-growth markets is important to our long-term future, including within semiconductor capital equipment, life science, automotive, robotics and general automation segments,” said David Doyle, HEIDENHAIN CORPORATION President and CEO. Other recent western territory additions include the opening of HEIDENHAIN offices in the Seattle, Denver and Houston areas. HEIDENHAIN’s John Thormodsgard is newly appointed as Western Sales Director.

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Mazak Announces Opening of New Expanded Spindle Rebuild Department As part of its most recent $15 million investment in its Florence, Kentucky-based manufacturing campus, Mazak Corporation has announced the completion of its newly expanded Spindle Rebuild Department, now located in the company’s South Building. The expansion coincides with other Mazak investments, including new Technical Centers in Northern California, Florida and most recently Canada, all of which have been developed to provide local manufacturers with fast and reliable applications expertise, training, service and support. To guarantee that all original spindle specifications are met or exceeded, experienced factorytrained technicians use only genuine Mazak replacement parts to

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IMD 9

Business 4.0

Factors Influencing Reshoring

The Ramifications of Coronavirus Against a Backdrop of Tariff Uncertainty

he ramifications of the coronavirus against the backdrop of tariff uncertainty have companies rethinking their supply chains and considering what to reshore. Even before 2019’s turmoil, the number of companies reporting new reshoring and FDI (foreign direct investment) was at the highest level in history in 2018. China sourcing costs had already been climbing, but disruptions from tariff uncertainty compounded by the coronavirus disruptions are influencing more reshoring. Current conditions warrant shortening supply chains to reduce risk and increase resiliency. Current conditions are accelerating reshoring.

Coronavirus Impact Many Chinese factories were temporarily shuttered due to the COVID-19 outbreak, disrupting global supply chains and affecting U.S. importers and manufacturers. Shipping companies reduced the number of seaborne vessels as a measure to stop the outbreak,

10 IMD AUGUST 2020

creating logistics bottlenecks. Countries restricted exports for their own self-sufficiency. As factory closings and logistics issues squeeze U.S. companies, many are considering reducing their reliance on China. Are the tariffs and the coronavirus, together, enough to seriously reconsider the benefits of localization and justify reshoring? A recent report by UNCTAD (United Nations Conference on Trade and Development) said, “the COVID-19 outbreak will potentially accelerate existing trends of decoupling and reshoring driven by the desire…to make supply chains more resilient.” According to a February 2020 Thomas study, 60% of U.S. manufacturers said business was impacted by the coronavirus and 28% were seeking alternative domestic sources of supply to increase resiliency. A May, 2020 follow-up study showed 64% of respondents were likely to reshore to North America, a 10% increase from March. A key finding from a separate June 2020 study showed 75% of respondents expected a significant or moderate increase in U.S. components.

Reshoring Case NYC, a handbag contract manufacturer, has received orders from customers that reshored due to the coronavirus. George Kabezian, a partner at Case NYC, says he has received orders from at least a dozen companies in recent weeks for work that would normally be done overseas. Atlanta-based G95 Inc., a manufacturer of outerwear with built-in filtration technology, reshored its supply chain from China to a Grand Rapids contract manufacturer amid the coronavirus outbreak. The disruption caused by the coronavirus outbreak in China left the company with over 1,000 unfilled orders. Carlton Solle, owner of G95 said, “As a business, if you don’t have anything to sell, you’re not a business, and you’re out of business pretty quick.”

Companies with Local Supply Chains Did Better During The COVID-19 Disruption The coronavirus pandemic revealed the vulnerabilities of hyper-connected global supply chains and companies with local supply chains faired better against the disruption. For example, toolmaker Stanley Black & Decker recently shifted production of its Craftsman tools from China to Texas. It reported no increase in costs and “much less impact from the coronavirus than would have been the case if it had remained in China.” Unilever has upwards of 200 factories worldwide and kept running at about 85% capacity. Unilever CFO Graeme Pitkethly said, “Most of our supply chain is local, it’s very flexible, and generally speaking the vast majority of the products we sell in a country we supply in that country.”

Tariff Uncertainty Bruce Kaminstein, founder of Cassabella, a cleaning and kitchen products company said this about the unpredictability of the tariffs, “How you price things, how you place programs with retailers, how do people go about hiring and capital investment: these are all impacted by the uncertainty.” As work flows out of China, companies that relocate to Southeast Asia are likely to find a less robust industrial infrastructure and rapid wage inflation due to small workforces. They will be forced to shift work again in a few years to India and then Africa. In many cases, it is more profitable and sustainable to shift to the U.S. now. Reshoring Initiative data shows approximately 30 companies brought production to the U.S. in 2018-2019 due primarily to tariffs, creating ~3,800 jobs. The tariffs and now COVID-19 are accelerating the shift out of China.

Transforming to Keep Up A recent BofA survey finds a "tectonic shift in global supply chains." More than 80% of companies in 12 global sectors in N. America, the EU and Asia-Pacific (excluding China), have “implemented or announced plans to shift at least a portion

12 IMD AUGUST 2020

of their supply chains from current locations.” Companies blame the shift on tariffs and the U.S.-China trade war but agree it is largely based on automation. As labor begins to represent a smaller share of total costs, companies that once offshored due to inexpensive labor rates are beginning to favor close proximity to the markets they serve. The study found that “companies in about half of all global sectors in North America declared intent to ‘reshore’.”

Can You Afford to Keep All Your Eggs In One Basket? According to the World Bank, China accounted for 33% of global trade in 2018, up from 1.2% in 2000. China manufactures nearly 25% of American imports and U.S. manufacturers rely on China’s factories for intermediate goods. In 2016, imports of intermediate goods grew 48%. Hyper-connected supply chains in many cases are so tightly linked that “shocks to a central hub such as the U.S. or China can very quickly become systemic and paralyzing.” Essential medical devices, PPE (personal protective equipment), and pharmaceuticals have been a prime example. According to the Department of Commerce, 97% of all antibiotics in the U.S. come from China. The U.S. imports of Chinese pharmaceuticals jumped 76% from 2010 to 2018 and U.S. manufacturers source 80% of their active pharmaceutical ingredients (APIs) overseas, primarily from China. China is also the chief supplier of APIs for producers in other countries. The FDA has already reported shortages of some drugs due to the disruption caused by the coronavirus.

Quantifying the Costs And Risks A broad range of costs and risks can be quantified using the free online Total Cost of Ownership Estimator®. TCO analysis helps companies objectively quantify, forecast and minimize total cost. It takes into account: freight and duty; travel expense and time; inventory carrying cost; warranty; intellectual property (IP) risk; impact on product innovation from having manufacturing distant from engineering; and the losses from stock-outs due to long delivery times. TCO quantifies many other factors, such as those associated with the risk of supply chain shocks or disruptions caused by natural disasters, political unrest or even a pandemic. Using this information, companies can better evaluate sourcing, identify alternatives, and even make a case when selling against offshore competitors. Before tariffs and the outbreak, about 8% of imports from China were more profitably sourced here, based on Ex-Works price. The 8% rises to 32% if the decision is based on TCO. With 15% tariffs also added, the share rises to 46%.

The Reshoring Initiative® tools and data can help OEMs make better sourcing decisions and contract manufacturers sell against imports. Resources can be found on www.ReshoreNow.org

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IMD 13

Talking Shop We test the equipment we repair – not just components, but the entire system – on stands that our engineers design prior to their return to service.

FEATURING:

TALKING SHOP WITH: Andrew Horner — Marketing Manager, Radwell International, Inc. Could you give us an overview of the company’s history, and who was involved? I’d be glad to. Jerry Radwell and Jim Speck founded Speck Industrial Controls in 1979. Later Jim left Speck and Jerry Radwell took over ownership, but health issues forced his son, Brian – the current president and CEO of Radwell International – to step up at a very young age to keep the company alive. This dedication paid off when he realized that there was a niche to be filled in terms of providing surplus parts and equipment to industrial buyers, who had nowhere to turn but eBay at the time. This epiphany led to explosive growth and allowed the company to move from approximately 7,000 square feet of space into a new 110,000 square-foot facility in 2005. That really marks the beginning of the Radwell’s upward trajectory toward becoming the global entity it is today.

Can you give us some idea of how the company is structured? You can break it down into four areas. The first is Industrial Electronic Repair for manufacturing and automated components, and the second is Certified Pre-Owned, or Surplus Parts and equipment. The third is New Equipment Sales from companies such as Baldor/ABB, Danaher Controls, Siemens, and SICK, among many others, and the fourth is Asset Recovery. This allows us to step in and assist manufacturers with surplus equipment they’re interested in selling. Scenarios run the gamut from a company with a warehouse full of obsolete equipment they’d like to clear out, to

14 IMD AUGUST 2020

a storage room filled with new automation and industrial electronic parts they no longer have any use for, to entire operations that are closing up shop and need to liquidate their automation assets. We will take inventory of these materials, make a bid, and then channel the results into the appropriate Radwell division, whether that be New or Surplus Parts.

How do you service your customers, and what is your geographic footprint? We have a mix of inside and outside sales representatives, a customer relations team, and a purchasing department that work in tandem to achieve our motto: “One Radwell working together toward a common goal.” This means that, in addition to an employee’s primary function, they are also trained to seek out additional opportunities that might benefit the customer. If they’re picking up a piece of equipment for repair, they might ask if the manufacturer has any new, old, or outdated automation items they’d like to get rid of in order to reclaim wasted space. Then they would share this information with our purchasing department, who would contact the company to discuss making a bid on the excess equipment. So it’s an intricate network that we’ve developed over the years, and a very successful one. I can attest to that myself by pointing out that there were about 50 Radwell employees when I joined the company in 1999, and there are now approximately 1,000 at nine locations around the world in the U.S., the UK, Canada, and Germany.

IMD – The Industry’s Most Extensive Industrial Publication

When it comes to surplus/ reconditioned equipment, I’m assuming that pretty significant savings can be realized. That’s true, generally along the lines of 60-70 percent over new, in fact. As an example, there was an automotive manufacturer who visited our booth at a tradeshow who had a Mitsubishi Drive that really did a great job for him, but it was somewhat dated and finding parts and repair services was getting increasingly expensive and time-consuming. While he was standing there we were able to determine that we had exactly what he needed in more than one location, and at a price so low that it literally left him speechless. Plus, we could handle repairs from that point forward, while also providing a two-year warranty, as we do on all our repair work and surplus equipment. In addition, we test the equipment we repair – not just components, but the entire system – on stands that our engineers design prior to their return to service. And that’s central to our business model: you can come to Radwell, buy new equipment, save money on surplus items, get your old stuff

repaired, and even sell off plant floor equipment you no longer need, all in one place. That’s a huge convenience you’re really not going to find anywhere else. For more information visit www.radwell.com

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IMD 15

Safety & Maintenance

The Importance of Technology Amid the Social Distancing Era By: Rob Hruskoci, Owner & CEO, Advanced Industrial Marketing

ne of the leading causes of workplace injury and potential death is heavy machinery accidents. The importance of man-to-machine protection has always been crucial to prevent these accidents; Power Industrial Vehicles (PIV)s are often mounted with technology to alert the operator of any nearby people. Due to unforeseen circumstances, a new growing threat along with heavy machinery is the need for spatial detection devices to be worn in order to maintain a safe social distance. COVID-19 has had a significant impact on manufacturers with more than 53% experiencing significant change - or total disruption - of operations, and 73% facing financial losses. The lack of personal

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IMD – The Industry’s Most Extensive Industrial Publication

protective equipment resulted in thousands of positive coronavirus cases from factories across the country. Advanced Industrial Marketing (AIM) is no stranger to proximity detection. For nearly a decade we have offered man-to-machine detection devices that have helped save lives in industrial, municipality, warehousing and manufacturing work environments. With the practice of social distancing being required by the CDC for the foreseeable future, AIM, like many companies, has pivoted our focus to introduce new social distancing technology to ensure companies and their employees are safe upon their return to work. AIM’s pedestrian detection devices have been upgraded to protect workers from each other in the event one unknowingly has coronavirus, expanding from their initial purpose of man-to-machine detection. According to the United States Department of Labor, personal protective equipment (PPE) is worn to minimize exposure to hazards that cause workplace injury and illness due to exposure to chemicals, radiation or mechanical workplace hazards. PPE varies across industries, including but not limited to protective eyeglasses, hard hats and safety glasses that are worn to protect the wearer against ‘something’ but never someone. PPE protects us from external dangers and until early 2020 there was no need for protection from fellow workers. This is where technology such

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IMD 17

as the EGOpro Active Tag and LASE PeCo systems, working along with standard PPE, can protect workers from external factors as well as preventing the transfer of the virus by allowing for proper social distancing practices. In a typical work environment, the CDC has stated that social distancing guidelines may be difficult to adhere to and nearly impossible to measure. The EGOpro Active Tag has been updated by introducing UWB technology in order to maintain the recommended six feet of safe distance between people, as opposed to assisting in keeping a safe distance from machines. In the instance that a social distance space has been violated, instead of a flashing red light to alert the operator of the presence of a nearby machine, the tag sends a vibration to alert both the tag on the individual and the person they’re interacting with of this breach. This technology is ideal for factories, warehouses and construction sites where it is often difficult to measure the minimum distance to keep employees safe. While this technology has already existed in the manufacturing and construction industries, these wearables can also be implemented into a variety of markets and industries in order to keep the general public safe. For example, going to the grocery store is an essential trip. Along with the precautions already in place at grocers such as plexiglass, one-way aisles and social distancing ques, the EGOpro Active tags have the potential to be embedded into shopping carts to help shoppers remain distant from each other. This is similar to installing the tags on PVIs in the industrial workplace. Each EGOpro tag contains a unique serial number, which is connected to a custom software, that documents which tag came within six feet of another tag for longer than six seconds. In a situation of an employee testing positive for COVID-19, the EGOpro would be able to determine who interacted with and was potentially exposed to the virus while being within six feet of that person. It’s contact-tracing capabilities use the serial numbers, assigned to each employee, to alert and take the proper quarantine precautions, all while keeping the identity of the persons involved confidential. Another application of these wearable devices is within tourism and popular locations. Currently in use at Magazzino Italian Art in New York City, guests are required to wear a tag upon entering the museum as part of their reopening plans and to protect guests while they enjoy their museum experience. A similar technology to the EGOpro, another device called the LASE PeCo, or “people counting”, helps people adhere to CDC recommended guidelines. PeCO is a way for public venues to measure traffic and building capacity using standalone 3D cameras to measure how many people are in a small space and a laser grid system to measure the number of people within an open or outdoor area.

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PeCo’s laser technology is smart enough to tell the difference between adults, children and objects, but is not capable of discerning gender or any other identifying features as part of a surveillance system. If and or when the system detects too many people in a given area, it can send an alert to the designated manager on duty to break up any overcrowded space. With the requirements for businesses or venues to re-open varying across all states, many nonessential businesses are opening their doors again at a limited capacity (e.g., 50%-75% occupancy). LASE PeCo is an ideal way to accurately manage the occupancy thresholds. The LASE PeCo technology can also be implemented within sports arenas and concert halls as quarantine protocols begin to lift, helping again to manage capacity limitations and thresholds The importance of keeping employees safe and healthy has always been a top priority for employers. In a social distancing era, that means adding an extra level of protection in order to prevent

the spread of COVID-19. Combined with existing safety precautions, technology can help limit the number of people in a given area as well as maintain a safe social distance from others, helping to create a safer work environment for staff and potential patrons and visitors. It’s vital for employers to adapt to this “new normal” and implement social distancing technologies as well as update protocols in order to maintain safety for all employees.

ABOUT ADVANCED INDUSTRIAL MARKETING Advanced Industrial Marketing (AIM) was founded in 1998 to bring technological innovation and safety solutions to major industrial companies across North America. With sales offices in Indianapolis, Chicago, Detroit and Atlanta, AIM’s team of seasoned professionals offers a full range of sales, consulting, procurement and technical services to a wide range of customers and industries.

ABOUT THE AUTHOR For more information, visit www.advindmktg.com Rob Hruskoci is the owner and CEO of Advanced Industrial Marketing (AIM). With more than 22 years of experience in the industry and an educational background in engineering from Purdue University, he understands the needs of his clients’ business and brings unique technology solutions to market.

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IMD 19

Manufacturing Showcase

Stor-Loc By Russ Willcutt

hen Stor-Loc was established in Kankakee, Illinois, in 1982, its products had already been proven to be world-class industrial tool and parts cabinets. Based on a design developed by Elux, a company located in Switzerland, Stor-Loc began manufacturing its cabinets in the U.S. in 1991, including all component parts, supporting the statement that its products are 100-percent American made. “These cabinets have been tested by time,” according to Mike Ryan, president. “We guarantee that they will be the best cabinet you will ever buy.” With all manufacturing taking place in Kankakee, Stor-Loc has built a global distribution network, serving the North American market primarily through sales representatives and distributors and overseas through private-label agreements. Interestingly, Stor-Loc does not build stock cabinets in advance and hold them in inventory, instead amassing all the necessary materials on hand ready for quick assembly, painting, and shipping, all depending on the customer’s required delivery date. “We have a standard lead time of four or five weeks,” Ryan explains, “but if the customer orders 10 and needs two immediately, they’ll get them. We have the equipment and the flexibility to meet their delivery requirements, and that always comes first.”

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This ability to deliver is augmented by a workweek extending from Monday through Friday, and until noon on Saturday, even extending into overtime whenever a backlog makes it necessary, as it has been in recent months during which the company has enjoyed record sales, Ryan notes.

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These “pre-engineered” cabinets provide a wide range of dimensions that will meet those required by any workspace design, in terms of height, depth, width, etc., and the drawers are chosen to fit the type of part or tool they will eventually carry. Stor-Loc technicians are available to assist customers in choosing the cabinets that will best suit their needs, even going so far as to provide what Ryan refers to as a “15-degree isometric drawing” along with the customer’s quote, allowing a glimpse into how the cabinets will integrate into the overall workspace design. The foundation of the company’s success, however, is the robust design for which its cabinets are known. Ryan points out that it was the first design to incorporate handles that ran the entire length of the drawers, and that the sheet metal fabrication of the cabinets protects the contents from both impact and environmental contaminants. Most importantly, however, are the ball-bearing roller carriages in its drawers. “We’re the only company that’s stuck to this important aspect of the original Swiss design rather than shifting over to slides, which are much less expensive,” he says. “But you’ll see the same Stor-Loc cabinet still operating smoothly when you’ve had to replace four or five of the others.” Asked whether automation and robotics have affected the role of tool and parts storage cabinets in the manufacturing space in any way, Ryan says there has been little change. “The fact is, you will

always need an operator at a CNC workstation, or a maintenance technician for a robot or cobot, and they will require replacement parts and tools. Think of it like this; when offices went paperless, filing cabinets basically disappeared from the workplace. But that can’t happen with tools and parts. And Stor-Loc cabinets are simply the best way to store tools and parts.” To learn more go to www.storloc.com

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IMD 21

Workforce Development

Partnering with Titans for Education

Mastercam Featured in TITANS of CNC Aerospace Academy with online tutorials that provide free CAD/CAM lessons for all

astercam, developed by CNC Software, Inc., is the featured CAD/CAM software in TITANS of CNC Aerospace Academy, which just launched on June 29th, to help train the next generation of highly skilled CNC machinists and eliminate the widening skills gap. Mastercam is one of the world’s leading CAD/CAM software. It is the most widely used CAM in industry and education worldwide. The software is popularly used in companies requiring precision machining, such as shops in the automotive and aerospace industries. TITANS of CNC Aerospace Academy is a project-based platform teaching high-level manufacturers the skills necessary to produce complex aerospace parts using the most difficult materials. TITANS of CNC, Inc. CEO Titan Gilroy and his team have worked hard to create the Aerospace Academy as a platform to highlight aerospace machining and processes, that gives users an inside look at the entire process of manufacturing complex, hard-to-machine parts, that are realistic to the industry. Mastercam is featured throughout the

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platform and content and is being utilized to produce the majority of the aerospace projects which live on the free Aerospace Academy website. “When we set out to build the game-changing Aerospace Academy, we knew from the outset that Mastercam was the only choice for a high-level CAM partner,” says Gilroy. “Just as our real-part inspired projects challenge users even at the highest level of programming, Mastercam is the greatest software, jam-packed with all of the tools manufacturers need to compete across all industries and meet the tough challenges and ITAR requirements. The Aerospace Academy is the next level of CNC education that will make a huge impact through the entire industry. We are proud to have Mastercam as a key partner in making this a reality.” “We are inspired by this next step with TITANS of CNC and the partnership with the Aerospace Academy,” said Meghan West, President, CNC Software, Inc. “There is no organization better suited to create this material than TITANS of CNC. It is well known that we are suffering from a lack of skilled workers in the manufacturing

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industry. That shortage is felt from entry level machining all the way to the highest level of precision manufacturing. This Aerospace Academy is where we will see the next generation of the upper echelon. This is where we will find those machinists that are going to innovate, it is where we will find those machinists that are going to push the boundaries, and it is where we will find those machinists that are going to shape the future of manufacturing. I am so excited to see how this training program is going to empower people to find careers in manufacturing that are going to change their lives and change the world.” TITANS of CNC will use Mastercam to produce additional aerospace tutorials, which will also be available on the Aerospace Academy website. In addition, they will be recreating their Rocket Series, Building Blocks Series, and The Art of Fixturing Series using Mastercam.

Streamline the Manufacturing Process from Job Setup to Job Completion Mastercam 2021 increases machining productivity and reduces overall production costs with faster and more flexible multiaxis improvements, improvements in turning and turning-related applications, advances in speed, safety, and much more. According to Meghan West, these advancements have been made in direct response to the needs of the global manufacturing community. “Mastercam is developed by listening to our users

and creating solutions for their problems. We adapt to changing needs to ensure that the customer experience is the best it can be as we continue to innovate for improved automation, efficiency, connectivity, and precision. From job setup through job completion, you can depend on our technology to empower productivity.”

Faster, More Flexible Multiaxis Programming As more shops continue to rely on streamlined multiaxis cutting for single-setup precision, Mastercam 2021 adds new techniques and strategies. Expanded Multiaxis Pocketing combines efficient pocket cutting with a focus on finishing with Accelerated Finish tools, automatically maintaining the correct tool contact within defined parameters. Mastercam now gives you the ability to analyze and modify the UV direction on surface models, expanding the power and flexibility of multiaxis flowline milling toolpaths. The new 3+2 Automatic Roughing toolpath automatically makes multiplane 3-axis roughing toolpaths by evaluating the model and stock, creating a cut, calculating what remains, and repeating the process until roughing is complete.

Advances in Turning and Turning-Related Applications Mastercam 2021 expands the support for modeling chucks and chuck jaws; you can now define them by selecting a solid model. Mastercam Mill-Turn supports collet chucks as individual component types which greatly expands the range of machines that can be directly supported. Mill-Turn Simulation has been added to the Mastercam Simulator interface so you can experience Mill-Turn simulation with the same interface tools as Mastercam Simulator. And, our Swiss machining solutions combine Mastercam Mill and Mastercam Lathe with specialized post processors. This adds machine-specific controls inside the Mastercam interface, delivering accurate G-code for a wide variety of Swiss machines.

NC Programming Speed, Safety, And Precision A new toolpath in Mastercam 2021, Advanced Drill, is a customizable multi-segment drill cycle that is useful for spot drilling, deep hole drilling, and back spot facing and each segment of the drill cycle can be defined and customized. And, when using tools with a tip angle, the

24 IMD AUGUST 2020

new Chamfer Drill toolpath chamfers holes after calculating the correct depth based on the desired width or depth, and lets you select holes of different diameters or sizes, or that lie in different planes, and machine them in a single operation with a single tool. When creating a bounding box in Mastercam 2021, the new Wrap option allows you to create the smallest bounding box possible. The new Check Tool Reach function lets you check your tool and holder against the selected model geometry to view where the tool can and cannot reach.

ABOUT TITANS OF CNC TITANS of CNC, Inc. has developed "TITANS of CNC: Academy" and "TITANS of CNC Aerospace Academy" and is the world’s leader in FREE manufacturing education, teaching the latest breakthroughs in CAD, CAM, CNC, and Metrology. Their online video-based curriculum is open to anyone regardless of age, technical savvy, or prior schooling. By focusing on the fundamentals of advanced manufacturing, students learn via the power of repetition, through a model that flips traditional

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manufacturing on its head and gets students hands-on with part design FIRST. As each part increases in difficulty new methods are added so the

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channel of authorized Mastercam Resellers in 75 countries, providing localized sales, training, and support for 2- through 5-axis routing, milling, and turning; 2- and 4-axis wire EDM; 2D and 3D design; surface and solid modeling; artistic relief cutting; and Swiss machining. For more information, visit www.mastercam.com

Are you still using welded nuts or inserts? Replace with Formdrill! #NoNuts Formdrills form sturdy bushings that can be threaded to produce your own inserts. These built-in inserts are as strong or stronger than the same-diameter welded nuts. Process works in steel, stainless steel, copper and aluminum up to ½” thicknesses. Standard UNC, UNF, NPT and Metric sizes are available up to 1.5” in diameter. It can easily be used in most Drill Presses, Milling Machines and CNC systems. Ideal for Automated Production Lines.

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New Technology

What Is Advanced Machine Engineering?

By: Bill Davis, Industrial Machinery and Heavy Equipment Industry Leader for Siemens Digital Industries Software

nnovative technologies are rapidly advancing machine engineering processes, driving positive change in the industry, prompting companies of all sizes to meet the challenges and trends facing machinery manufacturers. These trends include consumer driven customization, resulting in smaller lot sizes and product life spans; smart machines that provide an order of magnitude increase in information flow; hyper automation that leverages vast amounts of data to automate machine functions; and global competition from more flexible, agile startups. In response to these trends, advanced machine engineering (AME) has come to the fore in the past few years. It focuses on ensuring greater certainty in the development of next-generation machines by fostering collaboration among the multiple disciplines required to create today’s advanced machines. It also reduces ramp-up time to production through virtual design and commissioning, resulting in better upfront validation, shorter

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commissioning times and more immediate productivity. Equally important, advanced capabilities are now available to manage the entire bill of materials for all options and variants for advance machine builder support throughout its product life, from the engineering design through manufacturing, and service life.

AME Key Differentiators Let’s examine each of these powerful capabilities that form AME’s essential differentiators that are positively impacting the machine industry. Multi-disciplinary design – Today’s machines are no longer primarily a mechanical piece of equipment. Electrical motors and rotary equipment to move camshaft gears are driven by software and PLC codes, thus accelerating performance-based programs in recent years. The software is adaptable to conditions on the floor enabling the machine to react to real-time sensor readings. As more

IMD – The Industry’s Most Extensive Industrial Publication

mechanical capabilities and features are being replaced by software, machine designers must take into equal account the mechanical, electrical and fluids aspects of machine design. Multi-disciplinary design encompasses the complexities of building a machine, including engineering the design and manufacturing. It creates a single source of truth in design to address the back-and-forth process that exist between engineering silos. Blending capabilities and skill sets in a more collaborative environment ensures quality output of the machine design – so everything works together and has its place. It is more of an art form than simply bolting on electrical, sensors and cable-runs. Since it is an integrated solution, it creates harmony in the multi-disciplinary design that did not exist when disciplines were in silos. Virtual machine simulation and commissioning is the second differentiator provided by advanced machine engineering. This refers to how the machine proves itself or validates the software code in the virtual world before physically operating on the factory floor. The behavior of the machines is being driven by software, which is why simulating the code running on a virtual twin of the machine generates substantial dividends in time and resources. With virtual commissioning, the PLC software validates in a managed environment with a full modular product development strategy. Now machine builders can have the simulation upfront and link the software to the modules. This set up is a groundbreaking achievement for companies to be competitive in this space.

Moreover, virtual simulation provides a physical safety aspect because if the machine collides in the virtual world, it is substantially safer and less costly to fix than on a physical machine. Virtual commissioning drives the behavior of the motors, integrating that into the kinematics. This is powerful because a mechanism on a machine might move faster than expected, leading to an actual impact load greater than what was anticipated. Replicating the kinematics in virtual commissioning uncovers potential hazards leading to a swift resolution. Furthermore, by embracing virtual commissioning and visualization, machine builders bring customers into a virtual reality to interact with the machine in its digital form. From a financial perspective, this pays huge dividends because no one purchases a machine sight unseen. Also, they will not purchase it merely on a claim of virtually simulation via running software code. Therefore, a customer needs to substantiate that a machine works before it is shipped to their plant. A prime example of virtual commissioning is Tronrud Engineering, who for more than 40 years have developed, produced and delivered innovative machines and equipment. A digital twin of the new machine allows their designers, engineers, and programmers to work simultaneously and continuously interact and share their knowledge. By implementing virtual commissioning and simulation, Tronrud Engineering has reduced their commissioning time up to 70 percent, while compressing their engineering time by 25 percent. A substantial benefit to their bottom line.

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pressure hydraulic pumps with positive-seating checkball valves provide better wear and high volumetric efficiency. Pumps operate at pressures to 20,000 psi. Checkball pumps are ideal for hydraulic systems with demanding conditions and accommodate more force in a smaller package. At lower pressures, they provide the life and performance margin essential in critical environments. Checkball fixed displacement pumps offer flows from 0.22 to 60 U.S. gpm at 1800 rpm.

directional control valves…

• HP Pattern Spool Valves — Simple spool valves eliminate complex valve circuits for fourway control in high pressure systems. HP03 pattern valves are rated for 15 U.S. gpm at 10,000 psi, HP05 pattern rated from 5 to 25 U.S. gpm at 8000 psi. • NFPA/ISO Pattern Valves — Smooth spool movement with fourland design offers low pressure drop with large internal flow passages. 5000 psi valves rated to 165 U.S. gpm. • VST Series Seated Valves — High pressure with low leakage. Reliable shifting with non-silting ball-on-seat design. • Explosion Proof Option — Solenoids with special enclosures designed for use in hazardous locations. UL and CSA approved. • Accessory Sandwich Valves — Mounts under directional valves, saves space, reduces weight and provides flexibility locating valves.

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.

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IMD 29

Multi-disciplinary BOM and configuration management – A third differentiator of advanced machine engineering is the multidisciplinary bill of materials (BOM) for machine builders as they create more sophisticated, smart machines. It gives manufacturers greater flexibility to respond to customer demands for customization, as most modern machines are configured-to-order. Every machine, and every order, that a machine builder receives is often a new project. Consequently, machine builders need a way to track the diverse options, and variants, for integrating requirements along with project and change management, while managing the entire BOM throughout the product life. From the original engineering design, through manufacturing and then managing that machine bill of materials throughout its service life. A level of planning capability is required for each engineering discipline, providing a more agile approach. Also, there is a need for traceability of customer requirements, engineering requirements and activity that is performed by the mechanical design engineer, electrical engineer and controls engineer for executing the project. This includes the journey from a high-level customer requirements specification document through the BOM structure and attaching it to the actual task that is necessary for the deliverable. This process provides a level of capability for ensuring and reducing the risk in meeting customer requirements, enabling sophisticated software solutions that are implemented into every machine.

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Smarter Machines, Smarter Code, Smarter Software Advanced software is a necessity for machine manufacturers facing competitive globalization, shrinking margins, rapidly expanding customization, environmental and government regulations, as well as Industry 4.0 and other smart factory initiatives. In the face of these significant challenges, machines must be smarter. The core requirement includes machine design innovation in the operation and development process. Being good versus great depends on the quality and innovation in the automation code. Having great code provides intuitive user interfaces, promoting ease of use and taking advantage of new hardware capabilities. It’s using software algorithms to help machines move faster, more safely with less physical stress on components. However, having well-written code is not good enough. Current machines have enormous complexity in the lines of code. It is critical to test that code in a virtual world, running it through all use cases before loading it on a physical machine. Companies are under pressure to deliver highly customized machines rapidly, with added complexity. It’s no longer possible to rely on, and safely physically validate the machine. Every machine is released to the customer with a set of binaries representing the compiled machine operation and user interface code. With conventional practices, programmers scramble to get last-minute changes to the code locked in before the machine ships. In this chaotic environment, it is imperative to retain a locked version

of the final code to use for several purposes – service, catastrophic backup, lessons learned for future machines and upgrades to previous machines in the field. Therefore, having a code repository is not enough. Each software variant must be traceable and retrievable via the serial number for the machine bill of materials. A machine’s life needs traceable records of all upgrades in hardware and software representing the machines’ living digital twin.

Advanced Machine Engineering Moving Forward Advanced machine engineering solutions are emerging that address the challenges and trends facing the machinery industry. These include multi-discipline design, virtual machine simulation and commissioning and multi-disciplinary BOM and configuration management. The Xcelerator portfolio in Siemens Digital Industries Software suite of products provides a full suite of solutions to empower machine builders and suppliers with the essential tools to compete successfully, helping industrial machinery companies to transition seamlessly to create tomorrow’s complex, efficient machines.

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ABOUT THE AUTHOR: Bill Davis is the acting Industrial Machinery and Heavy Equipment Industry leader for Siemens Digital Industries Software. His experience and insights have been acquired from a career spanning 30 years in engineering and operations management with machinery and heavy equipment companies. Bill holds a master’s degree in Business Administration from Marquette University, with a concentration in Operations Management and Strategic Marketing, as well as a Bachelor of Science degree in Mechanical Engineering from Milwaukee School of Engineering.

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IMD 31

Process

Air Curtain Industry Introduces New Exciting Uses for a Mature Product

ndustrial air curtain applications aren’t new, but plant engineers are finding a host of new uses for the decades-old product. Air curtains became staples for dock and ground-level door energy savings during the second half of the 20th Century, especially after the 1970’s oil embargos and ensuing energy price rise. Since then, industrial manufacturers spanning every possible category opted to outfit door openings with air curtains to save energy. In facilities for aerospace, automotive, off-highway and other manufacturing categories where doorways range up to 16-feet-wide or 30-feethigh, energy savings is critical for plant operation budgets. Recently, plant managers are also opting for uniform temperatures for both employee comfort and product quality assurance. Industrial employee comfort has become increasing important especially in northern regions where cold open doorway drafts affect employee health and productivity and potentially lead to union grievances. Product quality assurance can be improved and parts production shrinkage can be decreased by providing minimal temperature variances near sensitive areas, such as computer numerical control (CNC) processes. Air temperatures near open doorways in winter can fluctuate temperatures tens of degrees and consequently skew critical tolerances required for precision cutting, stamping, punching and other CNC processes.

32 IMD AUGUST 2020

One example is a Miamisburg, Ohio-based metal preparation and fabrication supplier that was challenged by interior temperature fluctuations affecting sensitive production equipment near a shipping door. Industrial equipment dealer McCormick Equipment Co., Inc., Cincinnati, solved temperature fluctuations and significantly reduced production discards with an air curtain. McCormick installed a 12-foot long horizontal mount air curtain over the client's 12 (w) x 14 (h)-foot shipping door, which is open four hours/day, five days/week. Although quality assurance was the motivation, an energy audit was still performed to show the added benefits of an air curtain. Payback from energy savings alone was 1.01 years, based on 32 weeks of wintertime operation.

How Air Curtains Work in Industrial Applications Air curtain technology draws interior air from the facility and discharges it through field-adjustable (+/- 20-degree) linear nozzles that "seal" the doorway with a non-turbulent air stream meeting the floor approximately at the door opening threshold. A properlysized air curtain can contain approximately 70 to 80-percent of that air and return it to the space. An air curtain separates the indoor/ outdoor environments and effectively prevents outside air, dust and flying insect infiltration by discharging air ranging from 1,000

IMD – The Industry’s Most Extensive Industrial Publication

to 7,000 ft/min. velocities, depending on the door height and mounting height. The air curtains are typically activated by a limit switch or a smart control that can be programmed for a variety of opening and closing functions, as well as supplemental spot heating from optional on-board electric, gas-fired, steam or hot water coils. Air curtains can also draw wasted heat stratified at the ceiling via sheet metal fabricated plenums and distribute it back into the occupied zone. Smart controls can delay de-activation after the door closes and run air curtain heating until area temperatures are thermostatically satisfied. One recent innovation has made electric heating more efficient. Previously air curtain manufacturers put electric heating coils in the airstream, which inefficiently interrupted the air stream. Now, manufacturers are mounting electric elements at both air inlets of the blower housing to maintain an uninterrupted, laminar airflow from the blower to the air discharge nozzles for a more efficient doorway opening seal.

New Single Length Construction Another recent innovation from manufacturers is single length construction. Previously, the industry only offered shorter lengths that needed bolting together to cover doorway widths greater than 12 feet. Now single lengths are available in single lengths up to 16-feet with single custom lengths up to 24 feet. Single lengths don't create airstream disrupting obstructions as do models with multiple smaller lengths at their connection points.

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5:36 INDUSTRIAL MACHINERY DIGEST.COM 3/22/20 PM

Additional mounting hardware can raise project costs, because each length must be supported independently to prevent sagging even though they’re bolted together. Because single length construction uses heavier gauge, welded steel and internal beam construction, they need only ceiling-mounted threaded rods at the four corners.

Unusual Applications Sometimes end-users conceive of unconventional uses for air curtains, such as Coleman Tool and Mfg. Co., a welding, machining and metal fabrication manufacturing company specializing in replacement parts for waste disposal vehicles. Coleman installed air curtains for two 16 x 16-foot and one 12 x 12-foot overhead

doors at its 60,000-square-foot Union Grove, Wis., headquarters. The three units help maintain a 60°F plant wintertime temperature, which is generated purely from its welding process production waste heat. Using air curtains for energy savings is common; however Coleman had its air curtains modified to also filter airborne welding smoke and contaminants. About 20 percent of smoke evades the floor-level industrial air filtering walls positioned around the welding areas. The smoke results in a stratified blue haze above the plant floor. Consequently, Coleman’s maintenance department fabricated 24 x 24-inch steel filter racks that fit onto the air curtains’ air intakes. The racks are designed to use replaceable, off-the-shelf MERV-8 (minimum efficiency reporting value) pleated filters. MERV 8 doesn’t affect airflow performance and the hinged doors help expedite filter replacement in less than 10 minutes. The IAQ results have been significant. The haze is gone, the production floor’s air smells fresh, and the plant’s chronic asthma sufferers notice significant breathing improvements, according to plant executives. One important factor in Coleman’s air filtering success is the fact its building operates with a positive pressure. Some welding shops run under a negative pressure, which will adversely affect air curtain performance. Another recent innovation is hazardous location (HL) air curtains. Industrial buildings can be designated hazardous locations, because ignitable substances are prevalent, such as explosive powders, grains, chemicals or gasses, especially compressed natural gas (CNG). HL air curtains feature explosion-proof motors, sparkresistant fans, HL electrical components and construction, and other precautions required by ANSI/NFPA-70 National Electrical Code (NEC) regulations. Standard construction must comply with Class I, Division 1 and 2, Groups C and D for gases; and Class II, Division 1 and 2, Groups F and G for dust.

Anticipating the Payback on an Industrial Air Curtain Air curtains typically offer a payback of less than two years when considering energy savings. Plant engineers can perform their own free industrial door energy audit incognito and without post-audit sales pitches by visiting www.berner.com. The free energy savings calculator requires input data such as door size, cycles, hours of use and geographical region to automatically access utility electric/ gas rates and typical seasonal temperatures from NOAA. Once all the parameters are inputted, the energy savings calculator will provide an appropriate air curtain model selection, annual energy savings and payback.

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Getting Air Curtain Purported Performance When an air curtain manufacturer’s specification claims and the product’s actual performance statistics vary, the protection of a doorway has substandard efficacy. For example, an engineer might specify a particular discharge cfm, but an overstated specification in a manufacturer's catalog might result in poor performance and ultimately lost energy saving potential. Volume, velocity and uniformity of the air stream are critical factors in an air curtain's effectiveness; therefore it's important that air curtains perform up to manufacturers' specifications. The Air Movement & Control Association (AMCA-International), Arlington Heights, Ill., which is a not-for-profit organization that tests and certifies fans, blowers, air curtains and other air movement devices, created a test standard to assess air curtains and certify their performances. To assure an air curtain meets minimum standards, it should bear the seal of AMCA Standard 220, "Laboratory Methods of Testing Air Curtain Units for Aerodynamic Performance Rating." This is now a test that's an American National Standards Institute (ANSI) standard. Air curtain operation and applications have come a long way since they entered the North American industrial scene more than 50 years ago. They’re now staples of industrial energy savings, employee comfort and quality assurance.

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ABOUT THE AUTHOR: Michael Coscarelli has a B.A. in Business/Marketing from Indiana University of Pennsylvania and has been with Berner International, New Castle, Pa., for 36 years. He is currently the 60-year-old air curtain manufacturer's national sales manager. Berner offers free energy calculation at www.berner.com to determine a doorway's potential energy savings and payback when an air curtain is installed.

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IMD 35

Industry Insight

An Answer to Non-Stop Production

A high quality, efficient, and reliable screw CNC machine shop making two million parts per month, Swiss Productions implements two Productive Robotics OB7 cobots to operate their CNC mill machines, eliminating idle spindle time, maximizing production, and increasing productivity.

rom a family-owned company that started in a 750-square-foot facility with five screw machines, Swiss Productions grew to what it is today – a high quality, precision, and reliable screw machine shop producing over two million parts per month to customers worldwide in the medical, electronics, aerospace, and government industries. Located in Ventura, California, Swiss Productions today has over 50 screw machines and 30 secondary machines and produces components ranging in size from 2.5 inches in diameter down to syringe tips measuring 0.019 inches in diameter. Meeting the demands of their customers nationally and internationally while also maintaining the utmost quality requires constant innovation, forward thinking, and finding creative solutions to challenges. So, when faced with the challenge of maximizing their machine output and employee productivity, they quickly began exploring new solutions.

36 IMD AUGUST 2020

Minimizing Idle Spindle Time Swiss Productions faced a production issue on their CNC machines. Although they had the skilled operators to handle their machining, they were not maximizing their spindle time. One of their biggest challenges was keeping their Hass Mill machine running consistently. “The machine would only get 9 hours of production a day, and an employee would sit on the machine loading and unloading every 7-8 minutes, and take one hour worth of breaks a day,” explained Swiss Productions General Manager, Timo Lunceford. Production would also be interrupted if the machine operator lost focus while attending to other tasks. Swiss needed a way to keep their machines running 24 hours per day, generating more products while lights were out. Consequently, their machine operator was losing time to focus on other tasks while operating the machine.

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“Our operators would stand for 10 minutes, wait for the part to finish and then reload it. We were losing precious time that could be used more efficiently.”

Machine Tending CNC Mills with OB7 To find the answer to nonstop production, Swiss Productions investigated various collaborative robots on the market. They discovered Productive Robotics, and were immediately drawn to OB7. Swiss was attracted to OB7 in particular because of its seven

axes, which would provide the extra flexibility for handling their CNC machines. “When we discovered OB7, we knew the 7th axis for us is key. We are going in, grabbing the parts, moving sideways with them, and then blowing out the collets that we are using to hold our parts. We need a quick turn radius because we also have to teach it to close the door and then double check that the door is closed, and then be able to pivot to press the start button, which is a complete 180° from where it was,” states Lunceford.

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Integrating OB7 with the Haas Mill was accomplished entirely by Swiss employees, no outsourcing needed. In a few days, OB7 was up and running. Quickly working “lights out,” Swiss gained an extra 32 hours per week of machine running time on top of the normal 40 hours. In addition, they gained back the hours lost during breaks, bringing the total weekly production time up to 76 hours. Employee productivity was another priority for Swiss. With OB7 tending the machines, employees were able to take on other tasks to advance production. “The employee that would normally sit at the machine before OB7 is now able to run two of our smaller lathes at the same time. Previously, the cycle time wouldn’t allow for that between all three machines,” noted Lunceford. OB7 was driving higher output while also saving Swiss thousands of dollars monthly.

Plans for OB7 On Lathes And Other Machines Integrating OB7 into their machine shop has allowed Swiss to gain a competitive advantage by increasing their production and enhancing their team’s productivity. The success with OB7 was so valuable that Swiss Productions implemented a second OB7 to operate one of their other CNC mills.

38 IMD AUGUST 2020

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“We have not let go of any employees and our production has increased. We have big plans for OB7, not just on our mills but on our lathes we are producing parts as well,” Lunceford shared. With each challenge providing opportunities for growth and innovation, Swiss Productions is on their way to unsurmountable growth. With OB7, there are no limits to their future going forward in size, quality, and innovation.

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Established in 2010, Productive Robotics Inc. designs, manufactures and markets collaborative industrial robots and accessories used in diverse manufacturing processes. Its OB7 is the simplest, most flexible, easiest and fastest to teach collaborative robot in the market. These benefits have been achieved through design decisions, proprietary intellectual property, and a unique method of teaching rather than traditional programming. Productive Robotics aims to set the new standard for simplifying robotic automation. It emphasizes teaching the robot rather than programming. Its collaborative robots can be flexibly used in many applications offering simplicity, capability, and affordability. Productive Robotics was spun out from ZBE, Inc. ZBE, Inc.’s origin was in robotic camera systems used in motion pictures and television special effects. Through the years, ZBE, Inc. developed a wide technology base spanning robotics, motion control, digital imaging and printing, hybrid micro-electronics and high precision mechatronic systems.

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New Normal Manufacturing

New Normal Manufacturing Products and Solutions for manufacturing professionals during the ongoing COVID-19 pandemic. » For more New Normal Manufacturing, visit www.IndustrialMachineryDigest.com

Two-Person Lift Is Too Close Battling to adapt in the rapidly changing work, social, and health environments we find ourselves in, ensuring the safety of workers is more paramount than ever. Avoid the social distance concerns of the two-person lift by using a Sky Hook lifting device instead. The Sky Hook is a mobile, ergonomic lifting device designed to allow a single person to lift up to 500 lbs. Pick from the wide range of standard models or have a Sky Hook customized to best fit your unique application. Contact Sky Hook today! For more information, visit www.skyhookmfr.com

Dynabrade DYNA-FAST - Foot Activated Screening Thermometer Returning to work safely is priority one amid the Covid-19 pandemic. The DYNA-FAST Thermometer from Dynabrade is the latest innovation to help businesses resume safe operations. Fast, contactless temperature screening is an additional step every individual must take to ensure the health and safety of co-workers. Fast, self-screening upon entry each day takes only a few seconds and helps protect individuals, teams, work cell and customers. The DYNA-FAST features a Contactless Forehead Thermometer and has Operator-Free Scanning. DYNA-FAST produces an easy to ready Digital Output reflected into a mirror for instant results. Fahrenheit and Celsius available. For more information, visit www.dynabrade.com

HP Introduces First of Its Kind Polypropylene Material “The response to the COVID-19 crisis is a watershed moment for the industry. HP and its partners have 3D printed more than 2.3 million parts to bridge supply chain gaps, enable local production, and help healthcare professionals on the front lines,” said Ramon Pastor, Interim President of 3D Printing and Digital Manufacturing, HP Inc. The new HP 3D High Reusability PP, enabled by BASF, is a versatile, durable, and chemically resistant material that has been qualified for HP’s production-grade 3D printing systems, and is ideal for customers in the automotive, consumer, industrial, and medical sectors seeking an optimal balance between performance and cost. For more information, visit www.hp.com/go/3Dprinting

KINEXON SafeZone for Additional Employee Protection In May, KINEXON launched SafeZone, an accurate digital protection against the spread of COVID-19. The core element is a small lightweight ultra-wideband (UWB) wearable sensor, the SafeTag, which actively warns users if the minimum physical distance to another person is compromised. With optional software, companies can also trace chains of infection in order to take targeted action against the spread of the virus. In the future, KINEXON will work to implement a real-time localization system for forklifts and forklift drivers to help avoid collisions. For more information, visit www.kinexion.com

40 IMD AUGUST 2020

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Laserax’s New LXQ Laser Marker Redefines Ease of Integration and Remote Support Following COVID-19 After 2 years of development, Laserax releases the LXQ Fiber Laser Marker series. The laser’s features are not only aimed at reducing integration time and cost, but also at facilitating collaboration between system integrators and laser experts. To break the barriers of laser expertise, the system has a remote connection capability that can grant control of the system to a Laserax expert or partner anywhere in the world. Relying on a secure cloud VPN, this allows laser experts to better support integrators and end-users through remote services such as installation, training, after-sales support and live demos. For more information, visit www.laserax.com

Caster Wheel Kit Adds Mobility to Rockford Systems GermBlock™ Cough and Sneeze Shields "Giving GermBlock shields mobility is valuable where employees need physical separation in close proximity, such as working on assembly lines or in between fixed work stations whereby work patterns change," explained Carrie Halle, Vice President of Marketing & Business Development. GermBlock shields provide a physical barrier to help prevent the transmission of the COVID-19 virus, as well other harmful germs, liquid splashes and flying debris, by blocking airborne droplets. Available in 36-inch and 48-inch width versions, castor kits attach to GermBlock floor-mount shields so they can be easily moved to assist with social distancing and germ control. For more information, visit www.rockfordsystems.com

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IMD 41

Product Showcase

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

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

The SUHNER Robotools For Fully Automated Manufacturing 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. » For more information, visit suhner-machining.com

AMADA WELD TECH INC Introduces AC Inverter Welding Power Supplies The MIB-300A and MIB-600A AC Inverter Welding Power Supplies offer increased control resulting in more exact heat input and betterquality welds as compared to traditional AC weld controls. The AC inverter uses inverter technology with pulse width modulation (PWM) to produce and simulate an AC waveform. Unlike AC welders that use line frequency and depend on well-regulated facility power, the AC inverter can produce an AC frequency from 50 Hz to 500 Hz allowing more precise energy delivery in less time, is not affected by line voltage fluctuation, and provides a balanced three phase load.

ABB Makes Manufacturing More Sustainable By Recycling and Remanufacturing Thousands of Old Robots Remanufacturing enables existing robot users to sell inactive or legacy robots to ABB with an attractive buy back service, rather than scrapping them or leaving them unused in a corner of the factory. As well as previously owned robots, peripheral equipment such as controllers and manipulators are refurbished to “like-new” conditions at one of ABB’s Global Remanufacture & Workshop Repair Centers. Each remanufactured robot can also be upgraded to the latest controller, which unlocks new functionalities such as ABB Ability Connected services or the latest version of RobotStudio®, ABB's simulation and offline programming software. » For more information, visit www.abb.com/robotics

42 IMD AUGUST 2020

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Coxreels Offers a Variety of Stainless Steel Coxreels is pleased to offer various stainless steel grade choices to their customers, ideally servicing exact specification needs. Coxreels offers complete stainless steel reels and powder-coated steel reels with stainless steel fluid paths. Now customers can choose between 316 and 304 grade stainless steels for their fluid paths on many reel types to best match the necessary corrosion resistance of their reel according to the application. Coxreels stainless steel reel spools and frames will remain 302/304 grade stainless and are optionally available in an electropolished finish for additional corrosion resistance. » For further information, visit www.coxreels.com

Combi-CS Pedestrian Stacker Wins Prestigious IFOY Award Combilift won the Warehouse Truck Lowlifter Category with its innovative Combi-CS pedestrian counterbalance stacker. The Combi-CS is the only pedestrian counterbalance stacker that will operate in a conventional reach truck aisle for space saving and productive storage and handling. It features Combilift’s unique, internationally patented and award winning multi-position tiller arm which can be turned to the left or right of the unit to position the rear drive wheel, allowing the operator to remain in the safest position- at the side of the machine rather than at the rear as is the case with other pedestrian stackers. » For more information, visit www.combilift.com

C-FRAME PRESSES

AMI Launches M317, A Next-Generation Orbital Welding Controller With Touchscreen Interface, Data Analytics AMI, an ESAB brand, has launched its Model 317 Orbital Welding Controller. Designed for applications in the semiconductor, pharmaceutical, aerospace, nuclear and other premium pipe fabrication operations, the M317 contains the most modern controls and interface technology to simplify automated welding. This next generation orbital TIG welding system offers an unrivaled user experience through an advanced touchscreen that allows users to better control the weld, improving performance and increasing production efficiency. In welding mode, a data analytics engine provides live data, while cameras offer a live view of the weld.

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IMD 43

CNC Vertical Turret Milling Machines from Palmgren

With the enthusiastic response from HSS costumers to oelheld’s new SintoGrind HSS-X 1400 grinding fluid, oelheld claims that HSS manufacturers have long been neglected by grinding fluid manufacturers. There are simply no true performance oils available for the HSS market, in spite of the well-known fact that a performance grinding oil can have a huge impact on production efficiency and output. SintoGrind HSS-X 1400 is formulated with modern GTL (gas to liquid) base oils. It is suitable for flute, thread, profile, internal and external cylindrical grinding of steel materials such as HSS, PM and medical steels.

Designed for more complex workpieces, the CNC Vertical Turret Milling Machines offer strength and rigidity while providing greater versatility. The Turret Milling Machines from Palmgren are a cost-effective solution for every milling need. The milling machines produce more parts, faster and with better tolerances than standard manual machines. Another key feature is the Fagor Automatic controls that offer the most cost-effective solution in chip making profitability. This combination ensures faster programming, set-up and machining. Other features include variable speed drive, a heavy-duty spline motor drive system and vent air cooling system. Palmgren, now in its second century, is a C.H. Hanson brand.

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With measuring accuracy to .004” over 10’ this digital caliper measuring table provides repeatability to +.0015”. Accu-Table simplifies the quality control process of measuring overall part dimensions and is ideal for Fabrication shops, machine shops and anyone needing to critically measure long parts. Accu-Table easily makes critical quality control measurements of material up to 16 foot lengths. Using the measuring system’s Windows® Tablet PC, accurate inch/metric readings are calculated and stored for future reference. Also, the measuring information can be stored and accessed wirelessly over a network using Wi-Fi, Bluetooth or USB. » For more information, visit www.scotchman.com

• EZ-PULLER WORKS ON ROUND, HEX AND SQUARE STOCK.

Scotchman Industries Introduces The Accu-Table Digital Caliper Measuring Table With + .004 Accuracy

New Gear Motor Drive From Siemens Siemens introduces the Sinamics G110M, a motor-integrated drive for Simogear gear motors, offering flexible control, integrated safety, simple installation and a space-saving design. With a high degree of protection, up to IP66, this new gear motor drive provides the perfect solution to most material handling-related challenges, including conveyors, warehousing, logistics, baggage and cargo handling, post and parcel shipping, plus numerous industrial applications in the automotive, appliance and test stand industries. Simogear gear motors offer high torque density, low noise and high efficiency, and now with Sinamics G110M, it becomes easier for designers and system builders to integrate gear motors into a variety of control architectures.

New Antimicrobial Sponge Rubber from Trim-Lok Trim-Lok announces new Antimicrobial Sponge Rubber that not only meets DIN EN ISO 846 requirements but is also FDA compliant. Applications include use anywhere that the growth of bacteria on the surfaces must be prevented. Common applications include gaskets and seals used in medical, hospital, HVAC, refrigeration, transportation, food, pool, gym, and parks and playground equipment, and more. If your product will come in contact with skin, such as masks for face shields, Trim-Lok also has a line of antimicrobial sponge rubber gaskets and seals that are both EPA and FDA compliant.

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SPRINTER MACHINES…

Ultimaker Launches Ultimaker Essentials, Ultimaker Essentials enables companies to incorporate 3D printing in existing IT infrastructures and allows for seamless distribution and updating of 3D printing software. The paid subscription-based software offering addresses several glaring IT pain-points, including the need for improve management across workflows and the knowledge gap that exists in the manufacturing industry. Ultimaker Essentials also includes a brand-new direct support function and a catalogue of verified plugins to help effectively scale 3D Printing outputs. Subscribing to Ultimaker Essentials provides organizations with an enterprise grade solution for adopting a full 3D printing infrastructure. Users also have access to three eLearning courses from the Ultimaker 3D Printing Academy. » For more information, visit www.ultimaker.com

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ATTCO, Inc. DBA Syclone ATTCO Service — www.skyhookmfr.com ......................................... 23 Attica Hydraulic Exchange — www.ahx1.com .................................................................................. 41

YEARS

Betenbender Manufacturing, Inc — www.betenbender.com ......................................................... 5 Carell Corporation — www.carellcorp.com ...................................................................................... 15 Coxreels — www.coxreels.com ............................................................................................................. 9 Denver Breaker & Supply — www.denverbreaker.com .................................................................. 47 DHM Associates, Inc. — www.dhmassociates.com ........................................................................49 Dynabrade, Inc. — www.dynabrade.com ......................................................................................... BC Eagle Bending Machines — www.eaglebendingmachines.com ................................................... 15 Essex Structural Steel Co. — www.essexstructuralsteel.com ........................................................48 FABTECH 2020 — www.fabtechexpo.com ..................................................................................... IBC Formdrill USA Inc. — www.formdrill-usa.com ................................................................................. 25 H&K Equipment, Inc. — www.hkequipment.com ............................................................................48 HMI div of Betenbender Manufacturing — www.betenbender.com ...........................................43 HYPNEUMAT, Inc — www.hypneumat.com ........................................................................................ 7 IMDauctions.com — www.IMDauctions.com .................................................................................. 47 Kanetec USA Corp — www.kanetec.com ..........................................................................................48 Lenzkes Clamping Tools, Inc. — www.lenzkesusa.com ................................................................... 3 L&L Special Furnace Co., Inc. — www.llfurnace.com .....................................................................49 MacMillin Hydraulic Engineering Corporation — www.macmhydraulic.com ...........................29

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!

Morgan Manufacturing, Inc. — www.morganmfg.com ..................................................................49 Pro-Line — www.1proline.com ............................................................................................................49 Radwell International, Inc. — www.Radwell.com ............................................................................FC RAS Machine Tool Technologies Inc. — www.rasmachinetool.com ........................................... 33 Royal Products — www.mistcollectors.com .....................................................................................49 Schweiss Doors — www.schweissdoors.com ..................................................................................49 Scotchman Industries, Inc. — www.scotchman.com ................................................................... IFC Select Equipment Company — www.selectequipment.net ..........................................................46 Sprinter Marking, Inc. — www.sprintermarking.com ......................................................................45 Standard Direct.com — www.Standard-Direct.com ....................................................................... 47 Stor-Loc — www.storloc.com ...................................................................................................... 26, 27 Suhner Industrial Products — www.suhner.com ............................................................................. 19 Tormach — www.tormach.com .......................................................................................................... 13 Trim-Lok — www.trimlok.com ............................................................................................................. 31 US Industrial Machinery — www.usindustrial.com .......................................................................... 37 US Shop Tools — www.usshoptools.com ..........................................................................................11

50 IMD AUGUST 2020 IMDdirectory-TV-042020.indd 1

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Industrial Machinery Digest - August 2020

Articles inside

PRODUCT SHOWCASE

NEW NORMAL MANUFACTURING

INDUSTRY INSIGHTS

WORKFORCE DEVELOPMENT

NEW TECH

MANUFACTURING SHOWCASE

BUSINESS 4.0

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