Advanced Manufacturing Now

At the AeroDef conference in Long Beach, Calif., Lee Coleman, managing director of the U.S. machining division at Suhner, discusses the company's aggressive move into the robot tool area. He also talks about what his firm's new cooperative venture with PushCorp means for the future. And he gets into what impact composites have had on Suhner's business strategy in aerospace manufacturing.

In an interview at the AeroDef conference in Long Beach, Calif., George Barnych of B3 Technical Services details a demo project at the University of New Hampshire. The project addresses the promises of automation and IoT adoption. It explores ways to minimizing financial and technical risks for small and medium-size manufacturers. The underlying system is based on open standards. The project is being industrialized, and it is not yet open to the public.

At the AeroDef conference in Long Beach, Calif., Creaform's Payam Hariri explains who in manufacturing is using 3D scanning, as well as all the ways in which it is being used. It is a cradle-to-the-product-shelf tool tale: It begins with product development and ends with production and QA.

If you cut metal and make chips, machine tools are the lifeblood of your operation. Ryan Hegman, National Sales Manager, Caron Engineering Inc, talks with Chris Mahar, Associate Editor of Manufacturing Magazine, about how software and sensors can improve CNC machine tool life and performance. From better predicting and managing tool life and replacement intervals to maximizing precision through auto-compensation of tool wear, automating CNC machining is about more than robotics. Hegman shares how software and sensor automation can elevate your machining operations to the next level.

Smart Manufacturing magazine Editor in Chief Brett Brune interviews Stéphane Lannuzel, chief digital officer for operations at L'Oréal, in Paris. "The digital transformation of L'Oréal Operations is really led by our consumer needs. Our consumers have changed more in the last three years than in the past 30 years," Lannuzel says.

Manufacturing is growing more automated every day, and the fabrication industry is no exception. In this episode, Alan Rooks, editor in chief of Manufacturing Engineering magazine talks with Mark Scherler, general manager of FANUC America about the latest FANUC robot technologies for welding and cutting; how solutions for the Industrial Internet of Things may change how manufacturing operations are performed; and strategies for shrinking the Skills Gap in the U.S.

Manufacturing analytics allows companies to use data to drive more effective decision making. In this podcast, Alan Rooks, editor in chief of Manufacturing Engineering, talks with Eric Fogg, chief operating officer of MachineMetrics, about the role of the Industrial Internet of Things and Industry 4.0 in manufacturing analytics; key new apps from MachineMetrics (MachineMetrics Health and MachineMetrics Service); the results MachineMetrics is seeing with customers, including machine builders and manufacturers; and where the industry is heading regarding manufacturing analytics.

Do you know the exact amount of downtime for each of your machines? Jim Finnerty, Product Manager, Wintriss Controls Group, sits down with Chris Mahar, Associate Editor of Manufacturing Magazine, to talk about the value of automating data collection on the shop floor. Finnerty discusses the benefits over manual data collection and how businesses can capture data's low hanging fruit – getting the most return for the investment made. Learn how focusing on Overall Equipment Effectiveness (OEE) can improve your shop, benefiting worker and machine productivity while cutting costs and raising profits.

Think you know robots? Learn the facts in this podcast, when Chris Mahar, Associate Editor of Manufacturing Engineering magazine, talks robotics with Pete Rogers, Vice President, Operations for Acieta. Rogers talks about the challenges manufacturers large and small are facing and how robotics can address these macro issues. You'll learn how robots improve opportunities and utilization of workers, help companies solve their workforce challenges and what impact labor shortages are having on manufacturing operations. Rogers also highlights best practices for deploying robots within your current workforce and how to know if they are right for you.

Growing up attending SME chapter meetings with his dad, 2018 SME President Thomas Kurfess, PhD, FSME, PE, talks with Chris Mahar, Associate Editor of Manufacturing Engineering magazine, about his 35 years as an SME member and his year as SME President. Looking to the future, Kurfess shares his thoughts on how manufacturing can better engage and attract the next generation of professionals and what is next for the industry in 2019 and beyond.

The Skills Gap in the U.S is real and growing. In this podcast, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, talks with Jeannine Kunz, vice president of Tooling U-SME and vice president, director of training and development, about why manufacturers should be worried about the skills gap; factors contributing to the skills gap; and what manufacturers can do about it. They also discuss the Industry Pulse: 2018 Manufacturing Workforce Report; reasons why manufacturers should train their employees; what successful companies are doing to invest in their people; and the first step a company can take to start building a workforce training program.

The trend to robotic machine tool tending is picking up speed (as well as parts). In this podcast, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, talks with Stefan Drakensjo, Vice President, Robots & Applications - Global Business Line Manager – Handling & Machining for ABB. The discussion includes how to define robotic machine tool tending; the benefits robotic automation provides for machine tool material handling applications; the benefits of vision systems; and how workpieces can be handled with robots.

Automation doesn't have to be difficult. With the right strategy, job shops can install and use automation that keeps their companies competitive with larger firms. In this podcast, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, talks with Amanda Rosenblatt, marketing coordinator for Shop Floor Automation about her company's approach to automating machines; how easy it is for someone new to automation to pick up on this technology and start using it; and how Job Shop Automations' products integrate with automation or software solutions already in in use on the shop floor. The discussion also focuses on how job shops can use strategies for Industry 4.0 and the Industrial Internet of Things.

Sanjay Thakore, business strategy manager for Autodesk, talks with Candace Roulo, managing editor, about how the cloud brings data, people and machines together, and the challenges often seen in manufacturing environments and how they are solved by the cloud during IMTS 2018 in Chicago.

One of the key aspects of business that is sometimes overlooked is the partnerships that develop between independent companies. In this podcast, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, talks with Ben Mund, Senior Market Analyst for CNC Software, the developer of Mastercam CAM software about CNC Software's take on the value of business partnerships, how the company partners with developers and hardware and tooling manufacturers as well as other software companies, and the benefits to be found by collaborating with other companies.

Jay Elepano, optical CMM/SFG product manager for Zeiss Metrology LCC, talks with Candace Roulo, managing editor, about lasers, automation, cooperative robots and how to attract and retain a skilled workforce during IMTS 2018 in Chicago.

David Suica, president of Fastems LLC, discusses how automation and Industry 4.0 can be combined to help job shops overcome labor shortages and produce production. He talked to Senior Editor Bill Koenig at the 2018 IMTS event in Chicago.

Steve Baier, national sales manager of Haimer USA, talks about Industry 4.0 issues that job shops should consider. He spoke during at the 2018 edition of IMTS in Chicago.

Training in advanced manufacturing technology is a hot topic as companies grapple with the skills gap. In this episode, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, interviews Roger Tadajewski, Executive Director and CEO of NC3. Tadajewski explores the need for training in advanced manufacturing technology; how the industry can ensure that new workers are properly trained; how current workers can stay current with new technology; and how training will evolve and change in the coming years. He also explains how and why NC3 has formed a partnership with the SME Education Foundation, Snap-on Inc., and the L.S. Starrett Company to provide custom training in precision measurement for schools in the SME PRIME Schools network.

Wade Anderson, product specialist manager at Okuma America Corp., talks about his company's line of machine tools as well as the issues job shops should consider for automating their operations. He talked to Senior Editor Bill Koenig at the 2018 edition of IMTS.

Mark Johnson, president of Tapmatic, talks to Senior Editor Bill Koenig about the tapping industry and tap holders made by his company. Johnson talks about Tapmatic products that were on display at the 2018 edition of IMTS. The executive also talks about the economy and how it has helped Tapmatic.

Italian manufacturers have a lot to offer, both in their home country and in North America. At IMTS 2018, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine talks with Marco Saladini, Trade Commissioner, and Bart Pascoli, Project Manager North America for Machines Italia and the Italian Trade Agency in Chicago. Saladini and Pascoli explain the role of the Italian Trade Agency and its role in the manufacturing industry; trends in the in the Italian manufacturing industry; how the Italian manufacturing industry is approaching Industry 4.0 and the digitalization of manufacturing; and how the Italian Trade Agency provides information, support, and advice to Italian and foreign companies. They also explore the types of services that the Italian Trade Agency provides to Italian and foreign businesses that enable them to to connect with each other.

When you think of Bluetooth you might think about your phone, your car or that sleek pair of headphones and speaker you have. In this episode, Chris Mahar, Associate Editor of Manufacturing Engineering magazine, talks with Chuck Sabin, Senior Director, Business Strategy and Planning at Bluetooth SIG. Sabin explains how Bluetooth is used in the manufacturing and industrial sector; what Bluetooth mesh means for manufacturers; and what they found in their 2018 Bluetooth Market Update report. You'll learn that Bluetooth isn't just for consumers and how the technology is empowering manufacturing today and in the future.

Would you be surprised to learn that manufacturing workers are particularly vulnerable to personal financial problems? You'll learn about that and more in this podcast, in which Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, talks with Mike Domingos, Vice President, National Corporate Strategy and Distribution for Prudential Financial. Domingos explains why Prudential is concentrating on the manufacturing industry; key trends impacting manufacturers; and the correlation between these trends with the work Prudential is doing with its manufacturing clients. Domingos asserts that while there are some distressing statistics on personal finances for many Americans, particularly around the issues of budgeting and emergency savings, companies can help their employees navigate these rough financial waters through proper design and investing in a Financial Wellness program.

Kevin Kerrigan, senior VP in the automotive office at the Michigan Economic Development Corp., discusses how MEDC is helping Industry 4.0 gain traction in Michigan. He gets into how Michigan supports Automation Alley, which works to demystify new technology for smaller manufacturers, as well as LIFT and IACMI. The crux of the smart factory is being able to make, better, faster decisions, he notes as he describes the value the Industrial Internet of Things (IIoT) brings to Michigan factories. Adoption is "ultimately a matter of who wins," he adds. "And I think Michigan is in a very good place right now to do that."

SME CEO and Executive Director Sandi Bouckley on day one of IMTS. Among the topics: the future of manufacturing is increasingly digital; workforce development and training as a cultural imperative; and attracting and training the next generation in manufacturing.

Dean Phillips, founder and owner of Longevity Industries, an International Director for SME, and a Production Enhancement Engineer at LINK Systems, dives into how artificial intelligence (AI) and computer programs like Watson will help manufacturers achieve five-year goals. Watson, he notes, is helping manufacturers avoid the "garbage in, garbage out" phenomena that happens when people ask the wrong questions. He also describes standout opportunities for AI program applications. "We're trying to close the loop" with Big Data—without involving people all the time, he says. Less than 40 percent of U.S. manufactures in the U.S. have closed the loop, he said. And he weighs in on the workforce skills gap, the IIoT, system integration and predictive maintenance.

Inside today's machine shops, having 5-axis capability is no longer a luxury; it's a must-have. To price parts competitively, and to make a good profit, shops need to have the efficiencies 5-axis provides. Many shops are planning to make this move, so Advanced Manufacturing Now engaged Errol Burrell and Wade Anderson, product specialists at Okuma America, to discuss exactly how to make the transition from 3-axis to 5-axis machining in a painless way. In a highly entertaining exchange—it even includes a dance metaphor—they look at how 5-axis machining has evolved from a machine tool user's perspective and describe the pulse of the marketplace today. They go into detail on what kind of ROI shops can expect. And they review some of the reasons shops are moving up to 5-axis.

Eyeing what he says will soon become the world's largest workforce, "Motoring Africa" author Edward Hightower details how manufacturers can more profitably serve the growing African market by producing in six countries: South Africa, Morocco, Kenya, Ghana, Ethiopia, and Nigeria.

Manufacturers are living more on the edge these days—as in "edge computing" and "intelligence at the edge." In this podcast, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, talks with Diego Tamburini, Principal Industry Lead – Manufacturing Industry Experiences for the Cloud + Enterprise Division of Microsoft, about the definitions of edge computing and intelligence at the edge, why manufacturers need intelligence at the edge, the technologies involved, and the connection between these concepts and "smart manufacturing."

Manufacturers around the world are struggling to combat $50 billion of unplanned downtime per year. And so 5ME wants to give them the data "at their fingertips" needed for continuous improvement programs. The software 5ME is promoting for this is called Freedom. 5ME Executive Vice President Jeff Price gives a scenario of how a company can use Freedom, which he said is appropriate for anyone—"from the shop floor to the top floor." And he explains how companies can use the software with new or legacy equipment. Some customers are increasing their OEE by 20%. And along with that, some are taking days of finished goods out—saving millions of dollars.

There are many aspects of smart manufacturing that are evolving quickly, and simulation is one of them. In this podcast, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, talks with Christopher Parker, NCSIMUL Applications Engineer for SPRING Technologies, about the role of machine simulation and the role it plays in manufacturing, the industries where simulation is vital, and what the future of simulation looks like.

On the rare occasion that Manufacturing Engineering Editor Emeritus Jim Sawyer thinks about the intersection of insurance and manufacturing, it is usually in terms of fire, theft, personal injury and the like. However, in this conversation with Mike Domingos, VP of national corporate strategy and distribution at Prudential Financial, he learns of other challenges impacting people's financial wellness and how that impacts the manufacturing industry. Domingos explains what tools and programs are available to help people and organizations with these challenges. He also reveals what developments are in the pipeline to support financial wellness for both individuals and manufacturers.

Additive manufacturing has made tremendous strides in recent years and has advantages over traditional manufacturing processes in many applications. However, AM still faces significant barriers. In this podcast, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, talks with Matt Wise, CEO of Fisher Unitech about AM's current and future role in manufacturing, including innovative new applications.

Smart manufacturing, Industry 4.0, and the Industrial Internet of Things are all fast-evolving concepts that are changing how manufacturing processes are designed and implemented. In this podcast, Alan Rooks, Editor in Chief of Manufacturing Engineering magazine, talks with Ben Mund, Senior Market Analyst for CNC Software Inc., the developer of Mastercam CAD/CAM Software, about how companies are addressing these changes, including how parts are designed, programmed and manufactured. The discussion includes changes to toolpath development, evolution in manufacturing methods, and how manufacturers are dealing with growing "skills gap" in the manufacturing workforce.

Pete Rogers, a vice president of Acieta, discusses an impending "welding labor crisis" of a shortage of skilled welders. He talks about automated welding systems can take the load of repetitive welding tasks.

Duann Scott of Autodesk discusses developments in software for additive manufacturing. He talks about simulation and design for 3D printing with Bill Koenig, a senior editor of Manufacturing Engineering. This podcast was recorded at the RAPID + TCT in Fort Worth, TX, in April.

Sean Touhey, a junior in the manufacturing engineering program at Western Washington University, describes the innovation that led to his 5-person team winning the "design for digital manufacturing" competition for university students at RAPID + TCT. His team focused on eliminating leftover residue (sticky stuff on the dashboard), visual obstruction and airflow obstruction for cell phone mounts. Listen to find out what's next for Vent Buddy and the design team.

At the RAPID + TCT conference in Texas, Brian McLean, director of rapid prototype at Laika Entertainment, explains what led to his being awarded a Scientific and Engineering Oscar Plaque in 2016 for pioneering the use of 3D printers in stop-motion animated characters. He goes into the ways AM can be a competitive advantage, including precision, color accuracy, volume and repeatability. And he compares what he does with puppets to what manufacturers are doing in the medical field.

Dr. Mike Grieves, executive director of the Center for Advanced Manufacturing and Innovative Design at Florida Institute of Technology, explains ITEAM (Independent Technical Evaluation of Additive Manufacturing), which was recently introduced at RAPID + TCT. ITEAM is, he said, "a user-driven consortium to help advance AM faster than what is happening right now." The focus is on creating an information ecosystem that lets users answer "two core questions they always have to answer when they are looking at new technologies:" Can I build it with AM? (Is it technically possible?) And should I build it with AM. (Is it economically feasible?). GM, Infosys and SME are already involved.

At RAPID + TCT, Bruno Boutantin of Extrude Hone and Laurent Cataldo of Binc Industries speak about their firms' new joint offering: Finish 3D, for AM. It is, Cataldo said, "a full solution for the global market, for medium- and high-volume production series." It combines Binc's MMP (micro machining process) technology—a physical, mechanical and catalyst process "usually used to very low roughness levels"—with Extrude Hone technology for additive parts when they require finishing processes like AFM (abrasive flow machine) and CoolPulse. Finish 3D can be used in any market, he said: In addition to aerospace, "we do medical implants, and we can be used for tooling, for plastic injection mold, whatever, as soon as the volume can absorb the cost of the preparation and the fixture." Boutantin said the new offering lets customers for the first time "take any incoming roughness and … bring it below the micron." Getting to the sub-micron level is important in aerospace, for example, when manufacturers need to improve airflow in jet engine turbines, he added.

At the RAPID + TCT show in Texas, Chris Schuppe, GM of AddWorks at GE Additive, explains a new offering called AddWorks. He gets into how it came about, what it is, why it is needed, and what types of services GE is offering with it. Listeners who are already in AM can still benefit from AddWorks, said Schuppe, who details what automotive and medical customers have accomplished with AddWorks. "We've had challenges where we couldn't figure out the next steps in our (AM) journey," he said. "We lived that over the last 7-10 years. Now we are taking that as an external consulting service."

Roger Hart, research and development engineering manager of Siemens, talks to Senior Editor Bill Koenig about additive manufacturing at the RAPID + TCT Show in Fort Worth, TX. They discuss how Siemens is changing its strategy to use 3D printing. The company is moving to transition from rapid prototyping to "true manufacturing," according to the executive. Hart also talks about Industry 4.0 and other advanced manufacturing issues.

Bhuvi Nirudhoddi, an Ohio State University PhD candidate studying materials science and engineering, won the student poster challenge at SME's AeroDef manufacturing conference in California in March. She gives Advanced Manufacturing Now the 411 on her work—"Joining of aerospace alloys using high-speed impact welding"—and explains how she came up with the concept, as well as where she thinks it can make the biggest impact?

Chris Cagle of the South Bay Workforce Investment Board in Hawthorne, Calif., explains what his organization does, how the apprenticeship program works, and why such programs are so important. He enumerates employee and student benefits. And he speaks about his organization's work with SME to develop and register the first aerospace engineering apprenticeship occupation in the U.S.

Smart Manufacturing magazine Editor in Chief Brett Brune interviews Daniel Martinez, a member of the aerospace vertical market team at Siemens Industry USA, at the AeroDef show in California. Martinez talks about how Siemens adapted its CNC strategy to recent changes in the machining of aerospace/defense parts, as well as to additive manufacturing in aerospace. He also addresses the recent partnership between Siemens and Comau, and Italian robotics company.

Smart Manufacturing magazine Editor in Chief Brett Brune speaks with Suhner's Lee Coleman about high-volume machining and how the growth of composites in the market has impacted the Suhner tool strategy. (The company has worked in single-layer materials, such as SMC, CRFP, fiberglass and plastic, for years, but it has had to redesign & develop components/spindles to work in the STACK/complex materials market.) Among the challenges: Abrasive dust, a corrosive environment and, in aerospace, very dissimilar stacks. The Swiss company developed the STACKmaster in part to provide commercial aviation with small, lightweight and powerful units to drill these new complex stack materials. Coleman showed the new product at AeroDef in Long Beach, Calif., in March.

Smart Manufacturing magazine Editor in Chief Brett Brune asks EMAG USA CEO Peter Loetzner about new drivers in his company's A&D business model. The two discuss the trend toward more cell manufacturing. Loetzner talks about lessons he learned in his automotive career that have application in A&D—and explains why blisk manufacturing and power generation are EMAG'S sweet spots in A&D. He also details how Industry 4.0 is benefitting smaller manufacturers. And he provides insight about supply chain issues EMAG is taking on.

Smart Manufacturing magazine Editor in Chief Brett Brune speaks with Jon Jay of Ingersoll Rand Power Tools on how aerospace manufacturers can use digital data to understand and address quality risks in assembly processes. The pair discusses how the Ingersoll Rand QXN tools help aerospace manufacturers improve the quality of their output, make assembly operations more efficient and reliable—and save money. Jay also provides a before-and-after scenario about an aerospace manufacturer that replaced a traditional pen & paper approach to gathering data with a digital approach.

Amanda Pedersen, News Editor of MD+DI (Medical Device and Diagnostic Industry) and Qmed, discusses the trends and technology in the medical industry, such as artificial intelligence, surgical robots and virtual reality, and the opportunities and challenges associated with them. She also talks about UBM's presence at three co-located events in Boston on April 18-19: the Embedded Systems Conference, BIOMEDevice Boston and Design & Manufacturing New England.