MT Magazine September/October 2023

THE TOP 10: FOCUSING ON THE FEW by Douglas K. Woods | 01

LEAN AND GREEN THE MANDATES ARE CLEAR: IF YOU WANT TO BE A SUPPLIER TO MANY MAJOR COMPANIES, THEN SIGN ON TO ENVIRONMENTAL PRACTICES.

SUSTAINABILITY: SUSTAIN RESOURCES TO SUSTAIN YOUR BUSINESS by Tim Shinbara | 25

SUSTAINABILITY IS A BAD WORD by Stephen LaMarca | 30

by Gary S. Vasilash | 13

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SEPTEMBER/OCTOBER 2023 THE ENERGY ISSUE VOLUME 2 | ISSUE 5

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MANUFACTURING TECHNOLOGY

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A VIEW FROM THE WOODS

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The Top 10: Focusing on the Few

Chances are, you are reading this while taking a quick break before jumping back into your daily fray of people coming to you with what seems – at the moment – to be insurmountable problems; pressing emails flooding your inbox; or wondering why you haven’t heard back from a customer about a proposal

the best solution. Realize that you have people who stay close to tech developments that can be deployed to decrease cycle time or reduce the footprint of the system or otherwise come up with a better solution. That’s why they’re on staff. Good engineers are innovative problem solvers. Yes, the management decision may result in something that will fulfill the requirement, but it likely doesn’t do so in a creative, differentiated, imaginative, functional way, a way that will outsmart the competition – because the competitors’ managers might also be overinvolved in the development. Allowing engineers to do what they’ve been trained to do not only results in what is likely a better solution, but it (1) takes something off management’s plate and (2) allows people to learn and grow, to be engaged in what they’re doing every day. At a time when retaining staff is a challenge, the last thing that any organization needs is people who are indifferent or bored, who are likely to spend their time looking for their next employer rather than for a better way to execute the job at hand. Of course, empowering people to make decisions risks things going wrong. More to the point: Things will go wrong. But assuming that it is not a catastrophic decision that will take the company down, that wrong decision can lead to learning, which will result in a far better solution than can ever be realized in organizations where people are protected from the possibility of making a mistake. This is like bowling with bumpers in the gutters. Good for beginners but not the pros. And any organization needs pros to be successful. Putting the authority for decision-making into the hands of others allows you to focus on the critical few issues – the 10, not the 100. This may sound good to you. But it may also sound fanciful, something that you’re unlikely to put into practice because you’ve got all those hot-button items that you need to address. But I can tell you that as I travel around the world and visit shops and plants and manufacturing complexes of different types making an array of products, I’ve seen firsthand that the ones that are doing the best are those that have empowered their people, allowing their leaders to focus on organizational advancement. They focus on the top 10.

they’ve had for a very long time. We’ve all been there – or are there.

Back when I was running an automation company, we had a rather complex system that we codeveloped with a customer based in Ireland. When we started the debug process for the system, the president of the customer company flew to our facility. The list of things that we needed to debug for the multistation system – pneumatics, electronics, handling, hydraulics, etc. – was long, to put it mildly. The president asked us for a list of the top 10 issues. Just 10. So, we analyzed the long list and came up with 10. “Let’s talk about number one,” he said. We worked on that problem and solved it. Then number two moved up a place, and we took that on. It went that way throughout the debugging process. I learned a few things from that experience. For one, it is a whole lot easier to rack and stack 10 issues than 100. Knowing the top 10 allows for the sort of focus necessary to avoid being distracted by things that are not important individually but seem acute when aggregated. It became clear that it is important to have the discipline to focus on the critical few rather than the urgent many. Another thing I learned is people tend to pay attention to things that seem to be the most important at the moment. In terms of the long-term needs of an organization, many of those issues are trivial, but it’s hard to know that when it appears major. In order to achieve the right perspective, you may have to adjust what you see as your responsibility. Let’s go back to the example of building a complex manufacturing system. There are a lot of decisions to be made – which is why an operation has an array of designers, engineers, toolmakers, and other personnel on staff. Many of those decisions can – and should – be made by those people. Too often management becomes concerned that a wrong decision will be made, so they make it themselves. Not only is that demoralizing for the people who should be making the decision – I’ve never met a talented engineer who didn’t want to be fully involved in their project – but it is likely not going to be

Douglas K. Woods President AMT – The Association For Manufacturing Technology

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Table of Contents

Click See what’s trending on AMTonline.org

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Manufacturing Matters Get details on the latest industry news

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AMT Upcoming Events Important manufacturing technology dates and events to bookmark

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Lean and Green by Gary S. Vasilash

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The Big Picture A Sustainable Future Requires Manufacturing

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Get Ready for IMTS 2024! by Peter Eelman

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Innovation Revs Up: ‘Manufacturing Explorers’ Season 3 by Michelle Edmonson Sustainability: Sustain Resources To Sustain Your Business by Tim Shinbara

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Sustainability Is a Bad Word by Stephen LaMarca

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Positive or Grounded? MT Order Trends in Energy by Chris Chidzik

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COVER DESIGN Jacob McCloskey | Graphic Designer

INFOGRAPHIC DESIGN A Sustainable Future Requires Manufacturing Hailey Sarnecki | Graphic Designer

MT Manufacturing Technology (ISSN # 2836-2896), September/October 2023, Issue 5, is published bi-monthly by AMT – The Association For Manufacturing Technology, 7901 Jones Branch Drive, Suite 900, McLean VA 22102. Periodicals Postage Paid at Merrifield, VA and at additional mailing offices. POSTMASTER: Send address changes to MT Manufacturing Technology at 7901 Jones Branch Drive, Suite 900, McLean VA 22102.

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TECH REPORT Forget clickbait! AMT Tech Trends podcast hosts Stephen Lamarca and Benjamin Moses pull the news items that matter. Whether it’s 3D printed houses, robots on Mars or Le Mans and F1 racing, the Tech Report always keeps it fun and interesting. manufacturing technology industry content curated by AMT experts. Keep up to date with breaking news, white papers, analysis, market surveys, breakdowns, and actionable items from around the globe. At AMT, we mind your business.

CLICK

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Click MT Magazine is more than just paper pulp and ink. Explore our content on AMTonline.org and engage with discussions on a wide array of topics affecting manufacturing technology now.

Moving Up in 3D Glass ceilings were meant to be shattered. So, it should be no surprise that so many women are making manufacturing moves in the additive field. While we can’t highlight them all (yet), check out these profiles on three amazing women at the forefront of their fields and changing the manufacturing game for future generations – both male and female. AMTonline.org/article/moving-up-in-3d

IMTS+ Original Series Explores Motor City Manufacturers

Everyone loves a good road trip – seeing the cobots, learning about new tech, exploring vocational programs … What? Most people don’t do that on road trips? Well, Stephen certainly did on this season of “Road Trippin’ with Steve,” when he met some amazing manufacturers in Detroit. Take a pit stop to read about the new season (and watch it) today! AMTonline.org/article/imts-original-series-explores-motor-city-manufacturers

Infotainment Knock, knock! In honor of the 100th episode of the Tech Trends Podcast, make sure to catch up on recent episodes like this one. Ben and Stephen discuss everything from home improvement to additive manufacturing. If you’d like to see their lovely faces, you can also watch the episode on AMT’s YouTube channel! AMTonline.org/article/infotainment

International News From the Field: Europe Bonjour, mon ami! The Paris Air Show flew high as the aviation industry secured nearly $78 billion worth of orders and deals by the end of the event’s fourth day. Germany is also speeding toward another record-breaking year in robotics and automation. You can read this international report as well as ones for other regions on AMT Online. AMTonline.org/article/international-news-from-the-field-europe-31

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MANUFACTURING MATTERS

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Manufacturing Matters Check in for the highlights, headlines, and hijinks that matter to manufacturing. These lean news items keep you updated on the latest developments.

TECHNOLOGY

See Data, See Energy Energy consumption is ripe with opportunity for manufacturers. Applying the lean practices of identifying waste by using energy as a denominator will highlight a plant’s fascinating perspective. Ever wonder how much compressed air your shop wastes due to leaks? How about water usage for filtration? Don’t get me started on MQL! Shop visibility has grown beyond manufacturing equipment to encompass a holistic plant view, and harvesting data from manufacturing operations will maintain and improve the bottom line. Manufacturing consumes the second highest amount of energy only behind transportation. In the future, as manufacturers scramble to keep up with market fluctuations, energy efficiency will be the name of the game.

INTELLIGENCE

Alternative Energy Looking Sunny Over the past two decades, global renewable energy consumption has surged, almost reaching 45.18 exajoules in 2022, according to Kearny and KPMG. Approximately half of this consumption is attributed to modern bioenergy, while the recent expansion of capacity is driven by solar photovoltaics. Despite this impressive, nearly 15-fold increase, renewable energy use still falls behind fossil fuels such as coal, oil, and gas. Nevertheless, as energy demand continues to grow, renewables are poised to capture a larger portion of the market. In line with this, incentivizing policies are expected to play a pivotal role in reducing upfront costs for the global adoption of alternative energy solutions. Looking at worldwide investment trends in 2022, solar PV received the most substantial funding at nearly $300 billion, followed by onshore wind with $140 billion and geothermal at approximately $180 million.

SMARTFORCE

Smartforce on the Horizon Introducing the Smartforce Blog: Your source for news and announcements focused on the dynamic individuals and cutting-edge technologies driving the manufacturing technology workforce. Hear from the frontlines of education and workforce development as we highlight funding announcements, talent strategies, and inspiring stories from the K-12 robotics teams and STEM clubs that ignite inspiration across the nation. Visit us at IMTS.com/smartforce/ApprenticeBlog/articles.cfm. Coming in October: In honor of National Disability Employment Awareness Month, we are proud to present a three-part article series to recognize the contributions and achievements of manufacturing professionals with disabilities and the innovative organizations that enable meaningful professional and professional growth opportunities. This series delivers a deeper understanding of diversity in the workplace and what a thriving work environment can look like in 2023 and beyond. Watch for these stories and more on the Smartforce blog on IMTS+.

MANUFACTURING MATTERS

THE ENERGY ISSUE

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ADVOCACY

Regulations From the Biden Agenda Manufacturers are grappling with an onslaught of new and proposed regulations as the Biden administration seeks to advance its environment, trade, and social justice agenda. From toxic substances, such as PFAS and PIP (3:1), to labor rules, including overtime pay, to export controls of critical and emerging technologies, AMT is following developments to ascertain the impact on our members. It helps to share your stories of how a particular rule or regulation positively or negatively affects your business with your elected officials and with AMT at athomas@AMTonline.org. That data can persuade a regulatory agency that the cost is too great. In Congress, the REINS Act is a bill that would require any executive branch rule or regulation with an annual economic impact of $100 million or more to be designated as a “major rule” to come before Congress for an up-or-down vote before being enacted.

INTERNATIONAL

Sustainability Circles the Globe The concept of sustainability is important when selling manufacturing technology internationally, particularly in Europe. The European market, more than most, places a strong emphasis on environmental responsibility, demanding eco-friendly solutions that reduce carbon footprints and resource consumption. Offering a product or service that facilitates adapting to these practices not only aligns with the local regulations and mindset but also enhances a company’s reputation and branding. Sustainability-driven technologies generally lead to cost savings in the long run, which is a sales pitch in any language. Energy efficient and waste-reducing systems translate into lower operating expenses and increased profitability for factories. Moreover, many European countries offer incentives and grants to businesses promoting sustainable manufacturing, creating additional financial benefits.

Sustainability is a prerequisite for future-proofing manufacturing businesses in a world increasingly focused on climate change and reduced environmental impact. If you have something to offer, let us know so we can help you penetrate the markets.

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AMT Upcoming Events Learn more or register at AMTonline.org/events. Your datebook will thank you.

MTForecast 2023 October 4-6, 2023 | Detroit, Michigan INTELLIGENCE

MFG 2024 April 24-26, 2024 | Orlando, Florida TECHNOLOGY

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THE ENERGY ISSUE

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Lean and Green The mandates are clear: If you want to be a supplier to many major companies, then sign on to environmental practices. A great way to get started that can be hugely beneficial is to pull out that lean production manual that may be collecting dust on an office shelf.

BY GARY S. VASILASH CONTRIBUTING EDITOR

When the subject of the environment and sustainability comes up, some are all for it, while others, on their best behavior, roll their eyes and think, “I’ve got production schedules to meet; I don’t have time to do the things that people who don’t have the slightest idea about manufacturing think would be ‘good’ for me to do.” (Their less-than-best behavior would include an array of words that we can’t publish here.)

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The latter approach is usually from people who see doing things “green” as yet another thing they have to do – when they are already busy enough without adding more tasks and activities to what they are trying to accomplish. But implementing practices that minimize or eliminate (e.g., through different practices or via offsets) things like carbon in production materials and processes is becoming a requirement for suppliers at several companies that are working toward zero emissions in their own production operations. From Audi to Whirlpool, an ever-increasing number of global manufacturers are making zero-carbon pledges. Whirlpool has stated that it is committed to achieving “Net Zero impact of our operations by 2030 and creating shared value throughout the product life cycle.” And these companies aren’t just considering becoming carbon neutral within their own operations; this also includes suppliers. Audi has stated: “In 2025, on average, around 25 percent of total emissions that an Audi car will produce during its life cycle will be generated in the supply chain. To offset this, the company launched an ‘Audi CO2 program in the supply chain’ back in 2018. Together with suppliers, the program identified measures for CO2 reduction in the lower stages of the value chain.” Hard to imagine how they could emphasize suppliers more. The point is, while global companies are making it clear that they are committed to carbon neutrality, they are also making it mandatory that suppliers support those efforts. This Is Serious Ford, for example, has published the Ford Supplier Code of Conduct that explicitly states requirements that every supplier must meet, including: • “Know and follow this Code and align company policies to reflect these requirements.” • “Enforce a corresponding code of practice and require that subcontractors and suppliers do the same.” Which means that even second- and third-tier suppliers are included. And the company is serious about this. It states in large letters and bold type that suppliers must: • “Comply with or exceed Ford’s environmental requirements and policies, including all relevant Want to be a supplier to Ford? Then keep in mind that within the Ford Supplier Code of Conduct, you’ll find a requirement that states: “Eliminate waste.” Most major global manufacturers are committed to becoming carbon-neutral, and that extends to the activities of their suppliers. (Image: Ford)

national, regional, environmental, and chemical legislation.” • “Minimize their impact on climate change aligned with the United Nations Framework Convention on Climate Change (Paris Climate Agreement), striving towards carbon neutrality.” • Reduce, reuse, recycle materials in manufacturing. • “Achieve continual environmental improvement in manufacturing operations.” And there are details describing what is expected. What’s Expected Or take Boeing, which has more than 11,000 Tier 1 suppliers. In the company’s Supplier Code of Conduct, it states – and it is worth quoting at length because it underscores the importance the company places on the environment: “We expect suppliers to conduct their business in a manner that actively manages environmental risks across their operations, products, and supply chain.

“Suppliers are expected to establish an appropriate environment management system (e.g., ISO 14001 or equivalent), including policies and procedures aimed at effectively managing their environmental performance, and integrating environmental considerations into their product design or service. “Boeing considers climate change to be an urgent issue and expects suppliers to innovate in order to reduce the impact of The X-66A research aircraft from NASA and Boeing is part of the Sustainable Flight Demonstrator Project. It will be built using a modified MD-90. Not only is Boeing working with NASA to help develop aircraft that allow airlines to cut aviation greenhouse gas emissions, but the company expects its suppliers to innovate to reduce the impact of their processes and products on the environment. (Image: Boeing)

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How Steel Is Going Green In 1950, 189 million metric tons of crude steel were produced globally, according to the World Steel Association. Ten years later that amount nearly doubled to 347 million. In 1970, 595 million, then 717 million in 1980, and 770 million in 1990. At the turn of the century, the number rose to 850, then rose significantly by 2010 to 1,435 metric tons. By 2020 the amount of crude steel produced globally was 1,879 metric tons. There is plenty of steel being used to manufacture products of all types, as well as for construction and other applications, and that’s not going to change. The amount of steel used to produce things will grow. But there’s a concern – one that even the World Steel Association, the preeminent steel industry association, recognizes: “In 2020, on average, every tonne of steel produced led to the emission of 1.89 tonnes of CO2 into the atmosphere. In 2020, 1,860 million tonnes (Mt) of steel were produced, and total direct emissions from our sector were of the order of 2.6 billion tonnes, representing between 7% and 9%. of global anthropogenic CO2 emissions.” Yes, there are significant amounts of emissions associated with producing steel in the traditional way: About 70% of steel is produced with the blast furnace-basic oxygen furnace approach. The blast-furnace approach is based in transforming iron ore into pig iron using coke – which is made from coal – as fuel. There are some innovations in steelmaking that are being pursued, such as using green hydrogen to provide energy. Carbon Free Another innovative method is being developed by Boston Metal, a company that spun out of MIT 10 years ago. The company’s director of communications, Dawn Kelly, says the goal is to license the company’s molten oxide electrolysis (MOE) method to steelmakers by 2026. The approach is elegant in its simplicity. It takes carbon out of the process.

their products, services, and operations on climate change. “We expect suppliers to improve the efficiency of their energy, water, and natural resource usage, to minimize hazardous waste materials, to dispatch goods in adequate outer packaging and foster reusable/recycled packaging materials, and to responsibly manage their air emissions. “We expect suppliers to collaborate with Boeing to improve the processes and systems throughout the product lifecycle to protect the environment. Over time, we expect suppliers to establish environmental sustainability priorities and report their progress.” Those that roll their eyes when it comes to their manufacturing and the environment are going to find themselves with eyes wide open with surprise if they don’t begin to transform their operations to keep up with the requirements of these major manufacturers. While a given company may not directly supply aerospace, appliances, or automotive (just to name three), their customers could be doing so, and all of these companies are looking up and down the supply chain. Moving in the Right Direction While there are some clear issues within a manufacturing operation that need to be addressed in order to move in the direction of a more environmentally appropriate approach – like the issue of chemicals used in processes (which may actually fall under regulatory rules, so this isn’t something that is not just nice to address but legally required) – there is something that can be done that will have benefits across the board. Back in 1990, after the publication of “The Machine That Changed the World” by James Womack, Daniel T. Jones, and Daniel Roos, companies large and small started paying attention to lean production, which is defined by the Lean Enterprise Institute as: “A business system for organizing and managing product development, operations, suppliers, and customer relations that requires less human effort, less space, less capital, less material, and less time to make products with fewer defects to precise customer desires, compared with the previous system of mass production.” However, this isn’t an approach only valued by mass manufacturers. It benefits companies of all sizes.

CONTINUED ON PAGE 16

FEATURE STORY

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"HOW STEEL IS GOING GREEN" CONTINUED

Key Points Fundamental to lean are the seven major wastes identified by Taiichi Ohno, the father of lean. Not only can eliminating waste cut costs and improve quality, they also have ramifications that can help achieve green(er) operations. 1. Overproduction. This not only means excess product to the end customer but is also detrimental to the next step in the production operation. Making too many things is a waste of material and energy. 2. Waiting. During production operations, if there is a bottleneck causing subsequent operations to wait, odds are the machinery in the shop is still running but not adding value to parts. The energy wasted can be significant. 3. Conveyance. It is important to reduce the distance between operations within a facility, which saves both time and energy. Similarly, not only do supplier parks and reshoring help boost efficiency, but they reduce energy expended in transportation (which can result in emissions reduction). 4. Processing. Understanding what the end customer is willing to pay for can result in products that meet those requirements. Analyzing the operations performed in the context of customer requirements (as well as engineering issues) may lead to the elimination of steps, which reduces material and energy requirements. 5. Inventory. Ideally, no more inventory is on hand than is required to keep production flowing. Although the pandemic has changed what is considered necessary, excess inventories not only mean there are materials used and energy expended on components that may – or may not – be used, but the warehousing space can be a driver of waste (because it needs to be lighted and heated, for example). 6. Motion. This is primarily an issue at the operator level. The operator does things that can result in physical strain or which are a waste of time, such as searching for tooling. Ergonomics and 5S principles (sort, set in order, shine, standardize, sustain) are simply good business practices that, when deployed, can minimize operational waste, like repetitive stress injuries to operators who subsequently need to be temporarily replaced (getting that person is important, but it doesn’t add value). 7. Correction. Doing it again or scrapping it: clearly wastes of time, effort, and energy. Addressing these wastes can be hugely beneficial to operations – and can actually result in doing less. What’s more, by paying close attention to where waste might be found, you may naturally discover areas where environmental effectiveness can be achieved.

There is a containment vessel that includes an inert anode. That anode is immersed in an electrolyte that contains iron ore. Electricity (ideally produced from sustainable sources) is applied to the anode, and iron ore is added to the vessel. Kelly says, “We can use all grades of iron ore, not just the premium grades needed by other processes.” The anode heats the material to 1,600 degrees Celsius, at which point the electrons split the iron ore so there is molten iron, which falls to the bottom of the vessel from which it is removed, and the oxygen is vented from the top. Chemically: No carbon. Kelly says the process has been validated at lab scale and they are in pilot for the inert anode to operate at production levels. Realize there is not only the tremendous heat the anode must withstand but a corrosive environment in that vat, given the oxygen. What’s more, that anode has to last for an extended period of time. Consequently, there is significant metallurgy going on at Boston Metal to produce that anode. Fe 2 O 3 + eˉ = Fe + O 2

Inside Boston Metal: molten oxide electrolysis for the production of iron without carbon emissions. (Image: Boston Metal)

Asked whether the traditional steelmakers have any interest in what they’re doing, Kelly points out that leading global steel company ArcelorMittal is an investor in the company. As is BMW, so there is an interested user of the end product. Soon, it seems, the bar stock or sheet being processed in manufacturing operations may be a whole lot greener than it historically has been.

If you have any questions about this information, please contact Gary at vasilash@gmail.com.

FEATURE STORY

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TECH TRENDS PODCAST Take a listen at AMTonline.org/resources

TUNE IN FOR THE LATEST DEVELOPMENTS ON TRANSFORMATIVE TECHNOLOGIES.

INDUSTRY MARKETS Aerospace, defense, watches, energy, and more. SUPPLY CHAIN Silicon shortages, gas pipelines, reinforcing supply chains from the ground up. TRANSFORMATIVE TECH Machine vision, augmented reality, artificial intelligence. ADDITIVE MANUFACTURING AM advancements impacting everything from food production to automotive. ROBOTICS AND AUTOMATION Industrial robots, cobots, and lights out manufacturing.

THE BIG PICTURE

THE ENERGY ISSUE

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Produces multiple solutions simultaneously, reducing waste and allowing for more efficient solutions. Material efficiency, life-cycle assessment, and energy efficiency can be included in design parameters.

Recycled materials, closed-loop manufacturing processes, and waste management systems can lower production costs and reduce their environmental impact.

Utilizing alternative energies or optimizing energy usage requires manufacturing technology for solution design and development.

of manufacturers have a sustainability policy in place

are developing one

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Sustainable, localized supply chains across the manufacturing process can help reduce emissions and expedite production timelines. Reshoring helps not only with sustainability but with strengthening the U.S. economy.

Advances in manufacturing technology enable the solutions that make a sustainable future possible through increased efficiency, waste reduction, and smarter technology.

Allows better insights into the production environment, leading to smarter and more responsible resource management.

Streamlining manufacturing processes improves efficiency and reduces waste.

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SAVE THE DATE FOR

SEPTEMBER 9 – 14, 2024 MCCORMICK PLACE, CHICAGO

IMTS, the largest manufacturing technology tradeshow in the western hemisphere , showcases the transformative technologies that are enabling our industry to reach new levels of productivity and profitability.

STAY UP-TO-DATE AT IMTS.COM

IMTS

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Get Ready for IMTS 2024!

BY PETER EELMAN CHIEF EXPERIENCE OFFICER

“Inspiring the Extraordinary” is the theme for IMTS 2024 – The International Manufacturing Technology Show, taking place Sept. 9-14 at McCormick Place in Chicago, Illinois. Plans are underway for the world’s premier industry event, and people are thrilled about new

provide customers with the flexibility to take light to heavy depths of cuts. The new geometries are engineered to lower cutting forces for smaller machines in addition to offering excellent chip control when needed.” Melanie Lang, co-founder and CEO of Formalloy Technologies, believes the trend of adding AM equipment to move work in-house is growing. “The last few years opened our eyes to the instabilities in our supply chain,” says Lang, whose company provides directed energy deposition (DED) AM systems. “We can’t take delivery times for granted. Fortunately, we can apply technology to solve those problems.” As examples, consider large-scale metal additive technologies to replace forgings, castings, and tooling, which typically come from overseas and with long lead times. Other applications include out-of-date parts (notably for defense systems) or remote locations (e.g., military bases). “When you deploy additive, typically you can do most work on a single setup on a single machine without stocking a lot of extra parts,” adds Glynn Fletcher, president of EOS North America, the leading provider of laser powder bed fusion technology. “You can have a small installation very close to where you need it.” “The manufacturing and warehousing sectors remain optimistic, prompting company leaders to look at the big picture,” says Doug Burnside, vice president for Yaskawa Motoman. “From reshoring initiatives and workspace optimization to production capacity and workforce shortages, multiple issues are often at play when companies are looking to invest in automation technology.” Some of those technologies include robots that combine artificial intelligence deep-learning software with 3D cameras to create human-like vision and achieve pick rates of 1,200 to 1,700 per hour for a wide range of objects. Extremely fast and intelligent robots help companies meet order fulfillment demands, a trend driven by e-commerce sales, which grew to $272.6 billion in the first quarter of 2023, according to the U.S. Census Bureau. “Capital expense items have longer purchase cycles, so start evaluating solutions before the need becomes critical,” concludes Wigington. Register to attend IMTS 2024 at IMTS.com/Register and be inspired to create the extraordinary. EOS at IMTS 2022 showcasing the AMCM M 290-2 1kW system and Hyperganic aerospike rocket engine made with EOS technology and material.

technologies enabling manufacturers to be more innovative, productive, and profitable. The industry has witnessed remarkable advancements empowering manufacturers to think differently and create unprecedented solutions. “One year out from IMTS 2024 is a good time to assess efficiency, set new goals, conduct technology research, and plan equipment acquisition,” says Kevin Wigington, chairman of the AMT Show Committee and general manager for Select Production Technologies, a provider of CNC machine tools for high-volume production of complex parts. As examples of manufacturing efficiency, Wigington cites turning centers that combine multiple operations (e.g., milling, hobbing, and grinding) in one machine, pallet conveyors, and systems that use a sub-spindle or multiple axes to machine parts in a single setup to reduce cycle time and minimize geometric and shape defects. “Complement your

machine with any technology that can boost unattended run time,” adds Markus Stolmar, president and CEO of United Grinding North America. “For example, combination machining centers, tool

United Grinding representatives discuss the STUDER S31 with the CORE (Customer-Oriented Revolution) operating panel, shown at IMTS 2022.

measuring machines, and grinders now feature integrated tool changers, metrology equipment, and the ability to laser scan a tool or part to generate a 3D model.” Stolmar notes that machine manufacturers are offering compact, more affordable machines so that job shops can move work in-house. “IMTS showcases the full spectrum of cutting-edge technologies that lead to business growth,” he says. As part of moving work in-house, such as by adding a smaller machining or turning center, companies need to research cutting tools that match their needs, which often require a broader application range. For example, Kennametal’s KCP25C, a new steel turning grade, is designed to machine steels and PH stainless steels. “The new grade, depending on application, has been used in both P10 and P40 turning applications,” says Scott Etling, vice president of global product management at Kennametal. “New medium versatile and finishing versatile geometries also

If you have any questions about this information, please contact Peter at peelman@IMTS.com.

THE ENERGY ISSUE

IMTS+

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Innovation Revs Up: ‘Manufacturing Explorers’ Season 3 BY MICHELLE EDMONSON VICE PRESIDENT, EXHIBITIONS

Numbers matter in Season Three of “Manufacturing Explorers,” an IMTS+ Original Series, which premieres on Sept. 28 on IMTS.com. Here are three critical numbers encountered by show stars (and father-son duo) Max and Travis Egan as they explored the automotive

In the second episode, Max and Travis travel to Magna Electronics to meet up with another father-son duo, general manager John Cunningham and manufacturing engineer Alex Cunningham. If you drive a modern vehicle, chances are you’ve experienced one of the millions of sensors manufactured by Magna, including those used for cruise control, parking assist, object detection, and tailgate cameras. Watch as Max experiences one of Magna’s newer innovations, the Toyota Tundra trailer backup assist, then gets a firsthand look at how printed circuit boards are made.

industry:

2

The number of parts in the rear underbody section of the Tesla Model Y, down from 70 on the Model 3.

The number of electronic circuit boards printed each week at Tier 1 supplier Magna Electronics.

185,000

The temperature of a plasma column that synthesizes EV battery elements.

6,000° F

In the final episode of the third season, Max and Travis explore what might be the key to EV growth: the synthesis of lithium-ion anode and cathode battery materials. Based in North Andover, Massachusetts, 6K Inc. created the UniMelt ® system, a production-scale microwave plasma process that produces critical materials. Pour in feedstock at the top, zap it with an ultra-high temperate 6,000-degree plasma, and high value materials come out at the bottom. While conventional battery material production processes made from lithium, nickel, and cobalt pose geopolitical risks, cause mining damage to the environment, and are fraught with fair labor issues, UniMelt ® is a green process that enables a diverse and reliable supply chain for EV battery components leveraging both domestic and recycled feedstock. Season Three also bids a bittersweet farewell to its current hosts, as it’s the final season with Travis and Max. The show started with Max as a young mechanical engineering undergraduate and Travis introducing him to his world of manufacturing. After one pandemic, five years, two degrees, and 10 road trips with dad and a camera crew, Max is now pursuing his dream career as a lead analyst in the renewable energy industry. Buckle up and join Max and Travis Egan as they talk about the thrills of visiting innovative automotive companies in the premiere of the third season of “Manufacturing Explorers,” an IMTS+ Original Series, at IMTS.com/ManufacturingExplorers.

Season Three starts with a visit to Munro & Associates in Auburn Hills, Michigan. Sandy Munro, known as the “Teardown Titan,” deconstructs and analyzes vehicles, and he has particularly focused on EVs. The tour starts with Munro explaining the genius behind the Model Y design and really any design that consolidates parts for optimization. Munro calls items such as bolts “unfasteners.” Any design that eliminates a connection is one less thing to go wrong, and it’s something he happily points out as part of Munro’s redesign services.

Munro also answers Max’s questions about EV battery recycling and battery life (you’ll be surprised), explores the design of electric motors (they are only about the size of a basketball!), and provides insights into design and manufacturing efficiency. In a twist of fate, a fender bender at home provides the opportunity to rent a Model Y, and it’s a contest between Max and Travis to see who becomes the bigger fan and why.

If you have any questions about IMTS+, please contact Michelle at medmonson@AMTonline.org.

23 WATCH ORIGINAL CONTENT LIKE MANUFACTURING EXPLORERS

BROUGHT TO YOU BY

GENERATIONS COLLIDE IN THIS REALITY-STYLE SERIES

Buckle up and join Max and Travis Egan as they visit thrilling and innovative automotive companies!

On this season of Manufacturing Explorers , brought to you by Mazak , the father-and-son duo talks EV design and battery life with Munro & Associates, visits Magna Electronics to learn about manufacturing automotive sensors , and explores what might be the key to EV growth at 6K Inc.

Watch all seasons of Manufacturing Explorers now on IMTS+.

WATCH THE NEW SEASON OF MANUFACTURING EXPLORERS ON IMTS+ TODAY

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IS

AMT provides the tools and resources to capitalize on opportunities. Navigate shifting market conditions with the latest data surveys.Reach your goals with insights from top economic, market, and political analysts and forecasters. Find the insights you need. Learn more about AMT membership at AMTonline.org

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Sustainability: Sustain Resources To Sustain Your Business

BY TIM SHINBARA CHIEF TECHNOLOGY OFFICER

The concept of environmental sustainability often comes with biased, misrepresented, or even politically charged connotations. To help put sustainability into a more focused and business-minded perspective for the manufacturing industry, we want to get the industry on the same page and provide some context – at least to get conversations started. It’s a complex subject that will take some time for us all to fully understand and adopt, but at

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APRIL 24-26 | ORLANDO Connect with manufacturing technology industry leaders to address key business challenges and provide actionable solutions. Sessions cover a wide range of topics, including workforce, supply chain, leadership, politics, and more.

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the very heart of it, sustainability makes good business sense for many reasons. Earlier this year, AMT initiated a multipaper series regarding sustainability to help provide context, focus, and insight. So far, we’ve covered a brief overview of sustainability in manufacturing and the importance of water conservation in manufacturing. In the coming months, we will discuss the importance of choosing the right materials, reclaiming and recycling, and the technologies that can enhance sustainability. I encourage you to dive deeper into the sustainability topics covered in that series. These articles can be found at AMTonline.com/tag/sustainability. Fortunately, more manufacturers are developing their own policies and programs for environmental sustainability. A 2019 National Association of Manufacturers survey found that 71.9% of manufacturers had a sustainability policy in place, and another 8.3% were developing one. However, the meaning of sustainability and the ways to improve sustainable manufacturing can vary greatly from one organization to another. For example, leading into IMTS 2022, Siemens USA CEO Barbara Humpton stated through a press release: “Together, we will demonstrate that investments in decarbonization not only protect our environment, but bolster productivity and generate strong business results. Our collective action will shape the next century of American leadership and growth.” Her statement provided a holistic, collective interpretation of a sustainability mandate.

Creating Standards The biggest challenge for sustainability now is the lack of a common, industry-wide metric. It will take a concerted effort from industry leaders and trade

organizations such as AMT – The Association For Manufacturing Technology to advocate for, if not spearhead, the development of sustainability metrics and standards in such areas as carbon emissions, energy

WATER

and water use, reclamation, and waste reduction. So far, some of the most promising

SEWER

DIRECT COSTS INDIRECT COSTS

initiatives have focused on materials and reuse, such as the EPA’s Sustainable Materials Management Tools and the ISO 14040 framework series on life cycle analysis.

ENERGY

STAFF

In an effort to identify standards for product design, production, and recovery in the context of a circular economy, the ASTM International Committee E60 on Sustainability and the National Institute of Standards and Technology (NIST) recently conducted a workshop of key stakeholders. Earlier this year, a report was shared on that workshop’s findings, which cited the need to further develop, expand, and scale up standards around sustainability; integrate life-cycle thinking into product design with particular forethought paid to end of life options; refine and adopt best practices as more knowledge is gained through experience and as technologies advance; and educate the public on sustainability standards among other needs and areas of focus. In 2021, the Remanufacturing Industries Council (RIC) published the first American National Standard for Remanufacturing (ANSI RIC001.2-2021), which established specifications that characterize the remanufacturing process and differentiate remanufacturing from other practices. The guidelines are based on remanufacturing best practices collected by surveying large and experienced OEMs. At this point in the life-cycle of sustainability, the RIC’s work has proved commendable, and reviewing the standard provides key information and context for companies interested in creating new business opportunities in this area. What Sustainability Is and Isn’t The U.S. Environmental Protection Agency defines manufacturing sustainability as “the creation of manufactured products through economically-sound processes that minimize negative environmental impacts while conserving energy and

SERVICE

While Humpton and Siemens’ efforts are directly stated, some firms indirectly enable sustainability through their offerings, such as Xelevate in Leesburg, Virginia, a physical drone/ unmanned aircraft system (UAS) ecosystem proving ground. Xelevate is engaged by many drone/UAS companies for systems testing, development, training,

EQUIPMENT

COMPLIANCE

innovation, and demonstration. Their clients’ use cases vary from oil and gas production monitoring to forestry and gas emission-sensing analysis. Despite not having a direct mandate like Siemens, their services support the sustainability efforts of their customers, and that focus on sustainability impacts both operations and the environment. Even within the government, there is a slightly different definition focus for sustainability. The Department of Energy recently created the Advanced Materials and Manufacturing Technology Office (AMMTO), which “supports a globally competitive U.S. manufacturing sector that accelerates the adoption of innovative materials and manufacturing technologies in support of a clean, decarbonized economy.” The AMMTO does this through their mission “to inspire people and drive innovation to transform materials and manufacturing for America’s energy future.” Here, the DOE’s AMMTO aligns funding incentives to specific challenging areas of sustainability: materials and manufacturing technologies.