Advanced Manufacturing Now

Benjamin Fisk, general manager of 3D additive manufacturing for Methods Machine Tools Inc., discusses his company's 3D printing strategy. Fisk talks about the speed in which 3D printing is being adapted among manufacturers as well as his company's partnership with 3D Systems. He was interviewed by Senior Editor Bill Koenig during the RAPID + TCT show in Pittsburgh in May.

Tom O'Reilly, VP, Global Business Development at Rockwell Automation, details how his company's five-year plan to restructure its facility and supplier networks has led to a four- to five-percent annual improvement in productivity: "If you look at how we did/do it, here are some examples: inventory days dropped from 120 to 82. We reduced our CAPEX ... by 30 percent per year. Our delivery within our supply chain went from 80 percent to 96 percent. Our lead times were actually reduced by 50 percent. And then, for customer service, our delivery-to-customer want date went from 82 percent to 98 percent. And with regard to quality, we reduced our PPM by 50 percent."

SLM Solutions Software out of Austria is set to this year begin selling a new package to improve workflow in AM, SLM Solutions' Richard Grylls said At RAPID + TCT in Pittsburgh. "It will help to streamline the entire workflow--from the initial idea from the designer to geting it into the machine in one piece." He also talks about how OEMs can help a customer quality and certify metal parts. Grylls also discusses how selective laser melting is helping to speed up metal AM. And he gives an overview of process monitoring capabilities SLM Solutions is showing at the AM tech show, as well as emerging applications for SLM's machines (serial production of components in aircraft, space and automotive applications, for example). Lastly, he explains why SLM has a monthly user group meeting. Managing things as "a lone wolf" is a bad idea, he warns.

John Graham, senior product marketing manager for Ansys Spaceclaim, Ansys Inc., talks with Manufacturing Engineering Senior Editor Patrick Waurzyniak about how 3D modeling software can help manufacturers streamline designs and boost manufacturing productivity. With today's 3D modeling software, manufacturers are able to efficiently repair incomplete models, reverse engineer files, and incorporate powerful computer-aided engineering (CAE) software into manufacturers' toolbox to more efficiently create manufacturing processes.

Jeannine Kunz, vice president of Tooling U-SME, details how awareness of AM's capabilities is clearly on the rise: Some big manufacturers are focusing on what AM means to their human capital, and AM is often being incorporated into existing roles. Kunz also discusses how Tooling U-SME can help customers increase their use of additive technologies while the world waits for standards. Her division at SME leverages the knowledge of SME members to help companies work through challenges, including "make or buy decisions," she notes. And--the pièce de résistance--she previews the "first-and-only additive certification," at a fundamentals level: SME is set to announce it next month at RAPID +TCT (www.rapid3devent.com) in Pittsburgh.

Randolph Bradley, Technical Fellow in Supply Chain Management at Boeing, explains the Center for Excellence in Logistics and Distribution's reason for being, and Boeing's involvement with the industry-academia partnership. Among what is covered: energy use in the supply chain; demand forecasting using Bayes' Rule (also used to crack Germany's Enigma code during WWII), and insights gained from MHI's US Roadmap for Material Handling and Logistics.

Joe Lampinen, Senior Director, Global Practice Consultant for Engineering, Business, & Professional Services at Kelly Services, explores how manufacturers today must meet the challenge of engaging younger workers just entering the profession. These workers have the expectation that they will change employers ten times or more during their careers. Employers must be able to upskill and engage all of their workers and choose the right option from the many available for bringing in outside workers, including temporary workers, independent contractors, outsourcing, and consulting firms.

What's up with AM machines this year? At the Aerodef conference, SLM Solutions' Winthrop Sheldon takes on this and several other market-trend questions. "You're seeing more multi-laser systems. You're seeing generally more open systems (in terms of parameter control and material use). And you're also seeing larger format systems. So there are quite a few new trends that I feel SLM was instrumental in bringing to market. Now the question is can we maintain our position with these technologies—now that more of our competitors have, let's say, multi-laser systems."

Dimitrije Milovich, president and CEO of Radius Engineering Inc. (Salt Lake City), discusses the role small manufacturers play in aerospace. His company has fewer than 40 employees but has established a niche in aerospace. Milovich was at SME's AeroDef Manufacturing Show in Fort Worth, TX, where he received the 2017 J.H. "Jud" Hall Composites Manufacturing Award. He spoke with Senior Editor Bill Koenig about how small companies play an important role in aerospace manufacturing. Milovich also discusses advances in composites and what they mean for aerospace.

EnvisionTEC CEO Al Siblani explains why the SLCOM 1, a machine that does selective lamination composite object manufacturing and is in beta testing, is an important development in 3D printing: "There's absolutely no limitation in terms of geometry in terms of what kinds of composite parts you can build—unless it's a closed volume. Besides any closed volume, the SLCOM 1 allows you to additively manufacture parts that are 24 inches wide, 30 inches long and 24 inches deep. So what really makes the SLCOM an interesting product is its ability to print very large parts that could be used in some luxury automobiles as finished goods. It could also be used in a production capacity in aerospace companies." In part because of automation, SLCOM 1 promises to reduce to two or three days a manual manufacturing process that now takes about 13 days: making one GE90 engine blade in composites.

Zane Michael, director of thermal business development for Yaskawa America/Motoman Robotics Division, explains why the biggest challenge for welding manufacturers today is the shortage of welders. He notes that fabricators can apply robotic welding technology with a high degree of success by first using simple systems, and explains why human welders still play a major role in robotic welding by analyzing and managing the performance of robotic welding units.

At the Aerodef conference in Texas, Conrad Leiva, VP for product strategy and alliance at iBASEt and chair of the smart manufacturing working group at MESA, says companies should first evaluate their business model today to get ready for a smart manufacturing future. Next, they should look at their IT infrastructure. And don't forget to address digital handoffs between systems. "We're coming from a culture of silos and moving to a culture of collaboration--across our departments internally and into the supply chain."

For starters, NASA's HUNCH program brings projects, mentors, expertise and schools. SME's PRIME initiative brings mentors, equipment and a scholarship component. "It's kind of a big deal that those things mesh so well," says Blake Ratcliff, program manager of NASA HUNCH.

Sandra Rios, ‎Head of Product Management & Marketing, AXOOM GmbH, explores the development of the platform market for the Internet of Things, the company's vision for the IoT platform market, and its plans in North America.

At the Aerodef show in Texas, Mike Judge, executive vice president of Cincinnati-based 5ME, delivers the lowdown on cryogenic machining. He notes that 5ME can add cryogenic machining to machines in the field. (Installation takes 1-3 days.)

Bob Yancey, vice president of additive manufacturing at Altair Engineering, also discusses the importance of an upfront design process and advances in manufacturing simulation

The co-author of "The Smartest Places on Earth: Why Rustbelts Are the Emerging Hotspots of Global Innovation" discusses not only all he discovered in writing the book but also what he has learned since it was published. Example of the latter: "The movement from a focus on cheap to a focus on smart is ... a real competitive advantage, but it's not permanent. I discovered that China now very well understands that this is an issue. China is now the biggest buyer of robots in the world."

Steve Immel, head of Americas Business Development for Materialise, explains why a traditional manufacturing company may want to get into additive manufacturing, the main considerations for manufacturers looking to add capabilities in additive manufacturing, and explores the "triangle of materials, hardware and software."

Dr. Jeffery Ahrstrom, President and COO of BLM Group USA, explores how a tube laser system can help manufacturers replace the physical processes of punching, sawing and milling with lasing in order to reduce work-in-progress, improve upon existing manufacturing processes, and create new ones.

John Thompson, National Technical Sales Manager for PFERD Inc., offers his predictions on the future of metal finishing, examines new solutions that can help improve productivity and reduce risk in hand-held applications, and discusses how systems are changing to adapt to the growing use of composite materials.

Diego Tamburini, Senior Design and Manufacturing Industry Strategist for Autodesk, explores the main forces shaping the future of the fabricating industry; key strategies manufacturers can use to remain competitive; promising technologies Autodesk is currently developing; and the opportunity of the IoT for manufacturers.

Bonnie Martens, Marketing Communications Manager for Dimplex Thermal Solutions, examines key trends in process cooling; how chillers can be designed for energy efficiency; solutions that increase system uptime; and how the Internet of Things is changing how chillers operate.

John Galich, marketing manager for Mate Precision Tooling, discusses trends in the CNC punch press tooling and press brake tooling market; challenges facing the industry; and the evolving mission of Mate Precision Tooling.

John Heuring, Regional Sales Manager for Dallas Industries, explores the challenges fabricators face when their feed line operators process advanced, high-strength steels. He also outlines the special considerations that stampers should consider for feed lines being paired with servo presses.

Frank Arteaga, Head of Product Marketing for Bystronic, explains why Industry 4.0 isn't just for big companies and why small to medium-sized job shops should learn about and adopt it. He also explains how job shops can implement Industry 4.0 without making major changes to equipment and software.

Mark Scherler, General Manager of Materials Joining for FANUC America, explores how the Internet of Things is changing robotic manufacturing, laser processes that are being used with robotics, and how changes in the manufacturing labor force are affecting the need for robotics.

Craig Tomita, Area Sales Manager for Universal Robots, and David Jackson, President of CleanLogix (an OEM partner of Universal Robots) discuss the use of collaborative robot (cobots) in manufacturing. Cobots can be used without safety guarding on production and assembly lines, and CleanLogix has incorporated a UR cobot in one of its CO2 cleaning applications.

Will Healy, Strategic Marketing Manager, and Dave Bird, Key Account Manager, Metal Forming and Robotic Welding for Balluff Inc., discuss how press shops can dramatically improve uptime, tackle the biggest problems with sensors and networking in robotic welding, and surmount the challenges to implementing Industrial Internet of Things. They also explain how machine builders can increase the value they deliver to manufacturers.

Sandra L. Bouckley, FSME, 2017 President for SME, discusses the current state of the manufacturing workforce, what this means for the future, how companies can help bridge the skills gap and the role of new technology in resolving workforce challenges.

Charlie Miller, director of sales for the Eastern region of the US for the robot and applications group at ABB, examines emerging trends in robotic welding, how the Industrial Internet of Things is driving changes in the sector, and the biggest challenges users need to address--including the shortage of skilled workers.

Detlef Zühlke, Scientific Director for Innovative Factory Systems at the German Research Center for Artificial Intelligence and Executive Chairman of SmartFactory-KL in Germany, discusses what it was like to be a founding father of Industrie 4.0, obstacles to smart manufacturing and ways the transition can be made smoother.

Manufacturing Engineering Editor-in-Chief James D. Sawyer talks to Dr. Bruce Cameron, MIT faculty director, about the online professional certificate program. Online Education at MIT: Models and Methods to Manage Complex Systems MIT Professional Education's new four-course online professional certificate program, Architecture and Systems Engineering: Models and Methods to Manage Complex Systems is intended to provide a state-of-the-practice view on model-based systems engineering for technical professionals and engineers. This first-of-its-kind professional certificate was developed by leading MIT faculty and incorporates case studies, practitioner guest lectures and examples from a wide variety of industries and companies.

Guest: Met-L-Flow President Carl Dekker. Interviewed by Smart Manufacturing magazine Editor In Chief Brett Brune. How can we get around better? SME's 2017 Digital Manufacturing Challenge invites college and high school students around the world who are in STEM fields to answer the question—by creating forward-thinking, mobility innovation solutions. Contest submissions are due before March 13.

Smart Manufacturing magazine Editor in Chief Brett Brune discusses The Digital Transformation full-day seminar with John Deere's Craig Sutton. Sutton is the chair of the Nov. 9 event. The Digital Manufacturing and Design Innovation Institute (DMDII) is hosting it in Chicago.

Guest: Mike Molnar, Director - Advanced Manufacturing National Program Office, US Dept of Commerce. Interviewed by Smart Manufacturing magazine Editor in Chief Brett Brune. SME's Advanced Manufacturing Now talks with the US Dept of Commerce's Mike Molnar about Manufacturing USA, the new public named for the National Network for Manufacturing Innovation. Formally established in 2014, Manufacturing USA brings together industry, academia and federal partners within a growing network of advanced manufacturing institutes to increase US manufacturing competitiveness and promote a robust and sustainable national manufacturing R&D infrastructure. Hear the elevator pitch, and more.

Guest: David Morfas, Product Expert at the Plex Systems. Interviewed by Manufacturing Engineering Magazine Editor in Chief Jim Sawyer. SME's Advanced Manufacturing Now talks to David Morfas, who discuss how Smart Manufacturing is the convergence of several technology trends resulting in improved manufacturing productivity. It empowers manufacturers to be more competitive. This development promises to bring about a true revolution, with cloud technology enabling greater connectivity to people, machines and processes on the production floor and accessibility to actionable data like never before.

Guest: David Wick, Manager, Product Management at ZEISS Industrial Metrology. Interviewed by Manufacturing Engineering magazine Editor in Chief Jim Sawyer. SME's Advanced Manufacturing Now talks to David Wick, who discusses what ZEISS Industrial Metrology is planning for IMTS and new trends impacting the metrology industry today. We also discuss new products ZEISS Industrial Metrology plans to release in the upcoming months.

Guest: Dror Danai, Chief Business Officer at XJet Limited. Interviewed by Smart Manufacturing magazine Editor In Chief, Brett Brune. At the RAPID 2016 conference on additive manufacturing, Danai talks to Advanced Manufacturing Now about XJet's positioning—immediately after he showed the public XJet's liquid metal 3D printer and explained its new NanoParticle Jetting (NPJ) technology.

Guest: James Gorham, Executive Vice President at Fujitsu Glovia. Interviewed by Manufacturing Engineering magazine Editor Bill Koenig. SME's Advanced Manufacturing Now talks to James Gorham, who discusses what Fujitsu Glovia is planning for IMTS, how the industry has been changing and some of the products Fujitsu Glovia has in the pipeline.

Guest: Rodger Boswell, Vice President of Sales at Hydromat Inc. Interviewed by Manufacturing Engineering magazine Editor Bill Koenig. SME's Advanced Manufacturing Now talks to Rodger Boswell, who discusses what the company is planning for IMTS, how the industry has been changing and some of the products Hydromat has in the pipeline.

Guest: Howard Heppelmann, Divisional Vice President and General Manager, IoT Manufacturing Solutions, at PTC. Interviewed by Patrick Waurzyniak, Senior Editor, Advanced Manufacturing Media Following PTC's LiveWorx IoT business event in Boston inJune, Heppelmann talks to Advanced Manufacturing Now about PTC's role in the developing the Fourth Industrial Revolution. "I think this is a topic that comes along sort of once in a generation," he said, "and hopefully manufacturers recognize the opportunity that the Industrial Internet of Things or Internet of Things provides for them, as well as the threats, if they don't act."

Guest: Ed Youdell, President and CEO, Fabricators and Manufacturers Association, International. Interviewed by Sarah A. Webster, Editor in Chief, Advanced Manufacturing Media. Youdell talks to Advanced Manufacturing Now about what's new in the 5th year of Manufacturing Day, which will be held Oct. 7. The program has been a runaway success with more than 2,500 events in 2015, reaching more than 400,000 participants. AMN talks to Youdell about how to get involved. More information is available at www.mfgday.com.

Guest: Al Siblani, CEO and Founder, EnvisionTEC. Interviewed by Sarah A. Webster, Editor in Chief, Advanced Manufacturing Media. EnvisionTEC, a leading global manufacturer of professional grade 3D printing solutions headquartered in Dearborn, MI, and Gladbeck, Germany, has developed an all-new additive manufacturing technology to build composites. The SLCOM will be revealed for the first time at RAPID 2016 in Orlando, Florida.

Guest: John Fleming Executive Vice President Global Manufacturing & Labor Affairs (Retired), Ford Motor Co., interviewed by Executive Editor James D. Sawyer John Fleming began his career as an apprentice and concluded it as Ford's VP of Global Manufacturing, and talks about his involvement with Industry 4.0. Many in his position would reminisce about the past, Fleming, though is using his vast manufacturing knowledge to help others look ahead in his position as a director and advisor to SME's Smart Manufacturing Seminar Series.

Guest: Antoine Bisson, co-founder and chief technical officer of Poka Inc. Interviewed by Smart Manufacturing magazine Editor Brett Brune. SME's Advanced Manufacturing Now talks to Antoine Bisson about the "social industrial platform" he and a friend created to make training in manufacturing as easy as watching YouTube. It's all about avoiding mistakes and downtime. (We threw in a little Japanese lesson, too.)

Guest: Brian Glowiak, SME Education Foundation. Interviewed by Editor in Chief Sarah A. Webster SME's Advanced Manufacturing Now talks to Brian Glowiak, Director of the SME Education Foundation, about the need for a skilled workforce in manufacturing, and how SME and its longstanding foundation is actively working to fill the pipeline of skilled manufacturing workers through its Partnership Response in Manufacturing Education (PRIME) program and other outreach efforts.

Guest: Mohamed Abuali, CEO Forcam, Inc. Interviewed by Senior Editor Patrick Waurzyniak. SME's Advanced Manufacturing Now talks to Mohamed Abuali about Forcam's technology for promoting a digital manufacturing future, and why small and medium manufacturers need to learn more about the available technology and how it can improve their competitiveness.

Guest: Neil Desrosiers, Applications Engineer and Developer, Mazak. Interviewed by Senior Editor James Lorincz. SME's Advanced Manufacturing Now talks to Neil Derosiers of Mazak about the coming digital manufacturing revolution in advance of the MC2 conference to be held April 19-21 in Dallas, Texas. Where is this Internet of Things headed and is anybody really exempt from the future of manufacturing?

Guest: Al Albrecht, Author of "The American Machine Tool Industry." Interviewed by Editor in Chief Sarah A. Webster. SME's Advanced Manufacturing Now talks to Al Abrecht, the author of the book, "The American Machine Tool Industry – It's History, Growth, Restructuring & Recovery." The 91-year-old, who retired from a long career in the machine tool industry, gives his observations about the industry and where it's headed now. Albrecht last served as the Vice President of Textron's Machine Tool Division in Cheshire, CT, and has an engineering degree from The Ohio State University.

Guest: Jeannine Kunz, ToolingU-SME. Interviewed by Editor in Chief Sarah A. Webster SME's Advanced Manufacturing Now talks to Jeannine Kunz, the director of Tooling U-SME, about how workforce development is changing in an area where manufacturers struggle to find workers. Learn how ToolingU-SME helps small, medium and large manufacturers prepare a plan to keep their current workers on top of the latest technologies, develop ongoing training plans and ensure they can continue to grow with the workforce they need.