MT Magazine May/June 2022

THE AMT COMMUNITY OF INTEREST: EVOLUTION AND EXPANSION by Douglas K. Woods | 01

SMART MANUFACTURING AND THE SMALL MANUFACTURER COMPANIES OF ALL SIZES CAN BENEFIT FROM SMART MANUFACTURING TECHNOLOGIES. by Gary S. Vasilash | 13

WHY IS IMTS 2022 THE PLACE FOR JOB SHOPS? by Peter Eelman | 21

PRINTING PROOF: ‘FUTUREVIEW’ ON IMTS+ by Michelle Edmonson | 22

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MAY/JUNE 2022 THE JOB SHOPS ISSUE VOLUME 1 | ISSUE 3

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MANUFACTURING TECHNOLOGY

650+ Members in the Manufacturing Technology Community

Our members make, sell, service, and support U.S. manufacturing technology in a global market. We advance the industry by facilitating t he adoption of transformative technologies, producing community events, promoting MT standards, supporting international business growth, and enhancing industry knowledge. Make the most out of your AMT membership. Reach out us at membership@AMTonline.org.

MAY/JUNE 2022

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A VIEW FROM THE WOODS

The AMT Community of Interest: Evolution and Expansion

As companies learn to optimize their operations, particularly as staffing concerns continue across all industries and the movement to reshore and near shore gains momentum, interest naturally grows in robotics and automation. To help keep AMTmembers at the forefront of this important technology, we are excited to welcome Silicon Valley Robotics (SVR) into the AMT community. Andra Keay, the managing director and founder of the non-profit robotics organization, has joined AMT as vice president of Global Robotics. SVR has over 200 member companies that, as its name indicates, work at the leading edge of technology development. While “leading edge” is the kind of term that gets applied simply because it makes something sound cool, SVR is the real thing when it comes to the advance of automation. SVR members create leading robotics and automation technologies – at the cutting-edge of technology innovation. These are firms like Ceres Robotics, which makes equipment for the lunar surface; FLX Solutions, which has developed a one inch-diameter, snake-like robot to get into difficult-to-access spaces; Kestral Robotics, which develops harvesting robots. Of course, there are other SVR members, like Robotics Materials, which makes autonomous mobile manipulators for manufacturing operations, and the Toyota Research Institute (yes, that Toyota). It would be easy to say that the AMT community of interest is more than a century old. But the fact of the matter is, AMT is more than a century “new” – and with this affiliation with Silicon Valley Robotics, we plan for our COI to help create the future.

One of the terms that has really come into conve r s a t i on ove r the past decade is “community of interest” (COI). The Computer Sec u r i t y Re sou r ce Center of the National Institute of Standards and Technology (NIST) Information Technology

Laboratory defines COI, in part, as “a collaborative group of users who exchange information in pursuit of their shared goals, interests, missions, or business processes, and who therefore must have a shared vocabulary for the information they exchange.” What you may not know is that the organization that you now know as AMT – The Association For Manufacturing Technology was established in 1902. A group of machine tool builders created the organization to “exchange information in pursuit of their shared goals, interests, missions, or business processes.” Yes, a community of interest. And so, for the past 120 years, the members of AMT have continued to be a COI. But like any good organization, there has been evolution as things change in the environment at large. Whereas AMT’s focus was once all about machining metal – and for a good period of time, just ferrous materials – a series of changes has occurred to broaden its scope from just machines, tools, and fixtures to include the wider environment of manufacturing technology, from additive manufacturing to lasers to metrology to a toolkit of digital tools. For example, AMT established the MTConnect Institute for the development and support of a standard that links an array of shop floor equipment and systems. Without a doubt, one of the technologies that has had profound effect on manufacturing is robotics, a space from which AMT has long retained member companies.

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

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Editorial Team Mary Cecile Neville Director, Content mcneville@AMTonline.org

Executive Team Douglas K. Woods President dwoods@AMTonline.org

Membership & Sales Bill Herman Senior Director, Sales & Membership bherman@AMTonline.org

Kristin Bartschi Director, Marketing & Communications kbartschi@AMTonline.org

Travis Egan Chief Revenue Officer tegan@AMTonline.org

Technology Benjamin Moses Director, Technology bmoses@AMTonline.org Intelligence Ian Stringer VP, Data Strategy istringer@AMTonline.org Smartforce Greg Jones VP, Smartforce Development gjones@AMTonline.org Advocacy Amber Thomas VP, Advocacy athomas@AMTonline.org International Ed Christopher VP, Global Services echristopher@AMTonline.org

Chris Downs Director, Audience Development cmdowns@AMTonline.org

Peter Eelman Chief Experience Officer peelman@AMTonline.org

Kathy Webster Managing Editor, Content kwebster@AMTonline.org

Pat McGibbon Chief Knowledge Officer pmcgibbon@AMTonline.org

Dan Hong Writer/Editor dhong@AMTonline.org

Becky Stahl Chief Financial Officer bstahl@AMTonline.org

Jacob McCloskey Graphic Designer jmccloskey@AMTonline.org

Tim Shinbara Chief Technology Officer tshinbara@AMTonline.org

Tiffany Kim Graphic Designer tkim@AMTonline.org

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Peter R. Eelman Chief Experience Officer peelman@AMTonline.org

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Michelle Edmonson Senior Director, Events & Content medmonson@AMTonline.org

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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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2022 Upcoming Events Important manufacturing technology dates and events to bookmark

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Smart Manufacturing and the Small Manufacturer by Gary S. Vasilash

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The Big Picture Job Shops by the Numbers: Trends in the United States

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Why Is IMTS 2022 the Place for Job Shops? by Peter Eelman

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Printing Proof: ‘FutureView’ on IMTS+ by Michelle Edmonson

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Job Shops by the Numbers by Jan Schafer

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I Might Have Been Wrong About NFTs by Stephen LaMarca

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Machine Tool Orders Offer Clues Into Economic Trends by Chris Chidzik

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COVER DESIGN Jacob McCloskey | Graphic Designer

INFOGRAPHIC DESIGN Job Shops by the Numbers: Trends in the United States Tiffany Kim | Graphic Designer

MT Magazine (USPS # XXX-XXX), May/June 2022, Issue 3, is published bi-monthly (February, April, June, August, October and December) by AMT – The Association For Manufacturing Technology, 7901 Jones Branch Drive, Suite 900, McLean VA 22102. Application to Mail at Periodicals Postage Prices is Pending at McLean, VA, and additional mailing offices. POSTMASTER: Send address changes to MT Magazine, 7901 Jones Branch Drive, Suite 900, McLean VA 22102.

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JUNE 6-8, 2022

Even at the halfway point of 2022, NTMA has plenty of ways to give your business a spark!

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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.

AMT Partners With Silicon Valley Robotics To leverage the best each organization has to offer, AMT and Silicon Valley Robotics are partnering to expand markets for their members. The AMT community will gain exclusive access to SVR’s innovation, academic, and investor networks. SVRmembers will benefit fromAMT’s long-established industry knowledge and gain access to leading advanced manufacturers, as well as leverage AMT’s expertise in advocacy, market research, industry events, and global services. SVR Managing Director Andra Keay is now vice president of Global Robotics at AMT. Learn more at AMTonline.org/article/amt-and-svr-join-forces

Tune In to the ‘Tech Trends’ Podcast Join AMT tech fiends Benjamin Moses, director of technology, and Stephen LaMarca, technology analyst, as they share their DOPE (data on previous engagement) and vibe check the latest tech! They’ll discuss the hottest trends and breaking news on the cutting edge of manufacturing technology while exchanging hot takes, witty banter, and trippy tangents along the way. Released every two weeks, each podcast dives into the technologies transforming manufacturing – and the world. Listen now at AMTonline.org/resources#podcasts ‘Tom & Lonnie Chat: CNC 101’ Tune in to the next “Tom & Lonnie Chat” for a special program dedicated to workforce development with Professor Tony Schmitz from the University of Tennessee. Dr. Schmitz talks about his next generation initiative, America’s Cutting Edge (ACE), for machine tool technology development and advancement. With a focus on strengthening and advancing U.S. technical and manufacturing leadership, the ACE training initiative covers a wide variety of technical capabilities, including machining, CAM, work holding, process understanding and analysis, and a number of other topics that are critical to the modern shop staff. Join Tom and Lonnie at IMTS.com/watchTLC You’re Invited: ‘FutureView’ Premiere Event on IMTS+ “FutureView,” brought to you by ZEISS Industrial Quality Solutions, is an IMTS+ Network Original Series that documents the development of technologies that could revolutionize the manufacturing industry. Join the MT community for the premiere event of “FutureView” for an exclusive viewing of Season One and hear from AMT experts Tim Shinbara, chief technology officer, and Dayton Horvath, director – emerging technology, as they talk about the innovations that are changing our future. Save the date: “FutureView” premieres June 16 at 10:00 AM CT and 2:00 PM CT. Watch it on IMTS.com.

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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

Did Someone Say Data-Driven Decision-Making? The manufacturing industry is exploding with technology growth. The connected factory has created significant leverage for adjacent technologies to permeate the industry. The continued need by enterprises to seek value from data will create a vacuum for machine learning, cybersecurity, data infrastructure, and edge computing. And that is just the digital side. Additive, automation, and metrology are continuing advancements that directly connect with better products for the end user. This rapid pace of change may be alarming to some, but there are ways to tame this beast and get past the hype cycle. Understanding and assessing the value of new technologies and constant research on available and mature technologies will drive enterprises to make robust decisions.

INTELLIGENCE

‘Traditional B2B Sales and Marketing Are Becoming Obsolete’ “Most B2B sales and marketing teams typically function in a ‘serial’ or linear manner,” says Brent Adamson, Gartner LLC, in his February 2022 Harvard Business Review article, “Traditional B2B Sales and Marketing Are Becoming Obsolete.” The traditional sales process can be characterized as having two phases – marketing and sales – with a clear “handoff” between them. Adamson suggests that today’s digitally dominant buying behavior has rendered this linear approach obsolete. Alternatively, companies are addressing these shifting buyer behaviors with structural organizational changes, such as the Unified Commercial Engine (UCE). “Unlike traditional silos, mapped to internal processes, the UCE is built through careful mapping of customers’ buying journeys across a range of predictable jobs to be done.”

SMARTFORCE

BILT for Education and Workforce Development Programs A new working model for industry advisory councils has been developed in the IT industry that can easily be adopted to the manufacturing industry as well. The Business and Industry Leadership Teams (BILT) initiative prescribes seven common-sense tactics for success, including: focusing on single educational program disciplines; convening more frequent meetings; focusing on discussing industry trends, especially in technology advancements; assuring that post-secondary faculty attend all frequent meetings; conducting jobs skills validation and assessing required knowledge, skills, and abilities (KSAs) on an annual basis; conducting faculty crosswalks of KSAs to the curriculum being taught; and two-way communication to provide frequent feedback.

For more information, visit AMTonline.org/article/BILT.

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MANUFACTURING MATTERS

INTERNATIONAL

Opportunities Abound in Mexico Elsewhere in this issue is a nice piece about U.S. job shops with data that can certainly help you focus your sales strategy in this important customer sector. Speaking of which, have you looked across the border at Mexico? The job shop health there is impressive and a major contributor to the country’s industrial GDP growth of more than 4% this past year. There are more than 130,000 metalworking job shops in Mexico, with about 25,000 employing more than 15 people. The nearshoring phenomenon and recent regional trade agreement is keeping them quite busy in the automotive, aerospace, machinery, medical, and oil and gas spaces, among others. Same as here. However, in Mexico, the need to increase volume and complexity capabilities is huge. Translation: Opportunities! If you also offer training and in-house financing, you are a shoo-in. Tip: AMT has a Tech Center in Mexico to assist you in capturing this market.

ADVOCACY

Limited Progress on Tariffs President Joe Biden has primarily left in place the $350 billion in Section 301 tariffs on Chinese goods levied by the Trump administration, stating that China has made little progress in its commitments under the Phase One trade agreement negotiated in 2020. InMarch, some positive news came when the U.S. trade representative reinstated tariff exclusions in 352 categories of products out of a possible 549. The exclusions include specific machinery, electrical equipment, chemicals, plastics, and automotive parts and will apply fromOct. 12, 2021, through Dec. 31, 2022. Elsewhere, the United States and U.K. reached an agreement to partially remove Section 232 tariffs imposed by the previous administration on steel and aluminum. The new deal establishes a tariff-rate quota that will allow a certain amount of steel and aluminum to enter the United States without duties. However, shipments from the U.K. above that level would still be subject to the duties. Visit USTR.gov for additional information on U.S. tariffs and trade policy.

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WHAT’S HAPPENING

2022 Upcoming Events Learn more or register at AMTonline.org/events. Your date book will thank you.

CMTSE Exams SMARTFORCE

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The Certified Manufacturing Technology Sales Engineer (CMTSE) Program is the only nationally recognized program to measure and celebrate the skills, knowledge, and ability of sales engineers to perform effectively. Since 1993, more than a thousand individuals have taken the CMTSE exam and earned the CMTSE designation.

September 12-17 | Chicago, Illinois

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February 8, 2023 April 12, 2023 June 14, 2023 October 11, 2023 UPCOMING EXAM DATES

Job Shops Program Supply Chain Consortium Investor Forum Hannover Messe Conference Additive Manufacturing Conference IMTS 2022 CONFERENCES

Tech Leadership Summit Parts Cleaning Conference Industrial Laser Conference Women Make Manufacturing- Move Program

MTForecast 2022 October 12-14 | St. Louis, Missouri INTELLIGENCE

MFG 2023 April 26-29, 2023 | Phoenix, Arizona TECHNOLOGY

MTForecast brings the latest economic news, forecasts, and industry trends straight to you. Industry leaders, executives, and key decision-makers will connect and learn better business strategies through customer industry insights, economic forecasting, and deep dives into market data.

Save the date for the 2023 MFG Meeting! The Manufacturing For Growth (MFG) Meeting is the ultimate gathering of manufacturing technology minds, bringing together a community of solutions and solvers. Learn how to keep pace with growing demand, make lifelong connections, and see what opportunities lie on the horizon.

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Written by Dan Hong // Illustrated by Jacob McCloskey

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I think I liked getting to know the technology!

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Smart Manufacturing and the Small Manufacturer Companies of all sizes can benefit from smart manufacturing technologies. As larger companies work to develop more resiliency in their supply chains, smaller manufacturers who don’t avail themselves of the tech may find themselves no longer a link in the chain.

BY GARY S. VASILASH CONTRIBUTING EDITOR

Let’s face it: When it comes to things like video analytics, artificial intelligence and machine learning, autonomous mobile robots, and other advanced manufacturing technologies, it is very easy to figure that they’re being deployed with comparative ease in facilities of companies like General Motors, Boeing, or Caterpillar. After all, these

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Take video analytics. Bergstrom says the tech can be deployed in any size facility, whether it is a company the size of GM or a bracket manufacturer with one line and one facility that is supplying a company like GM. “Video analytics is about each step in the production line, improving quality.” As quality is a goal by a company of any size, the technology can be advantageous. Robots present a similar case, he says, if the task is line side loading; thenagain, the sizeof theoperation isn’t that important. “Other than economies of scale in terms of purchasing power, robots and cobots are just as deployable on a single line as they are in a facility with several.” He adds, “They are very applicable to small shops.” Bergstrom does point out, however, that artificial intelligence and machine learning are more applicable to installations where there is more scale. “In order to program and drive those algorithms – the more lines and the larger the network, the better off your AI and machine learning will be. “This is not to say smaller organizations can’t use them, but they’re more difficult to deploy, especially if it is in a single threaded, single-line, mom-and-pop shop.” That point segues into one where there is the question of labor. “Whether you are big or small, our view is that there is a transition going on as we speak,” he says.

are organizations that operate major manufacturing sites that have resources which can make many manufacturers awfully envious. But here’s something to keep in mind: According to industry research organization IBISWorld, as of 2022, there are 638,583 manufacturing businesses in the United States. The greater part of that number consists of those with fewer than 500 employees, which is certainly not where GM, Boeing, and Caterpillar are in terms of headcount. (Here’sa funfact fromtheU.S. SmallBusinessAdministration: There are 31.7 million small businesses in the United States across all industries and 20,139 large businesses, which means that small businesses represent 99.9% of all firms.) Small Like All So, what about video analytics, artificial intelligence and machine learning, autonomous mobile robots, and other advanced manufacturing technologies – do they have applicability in small businesses? “One hundred percent yes,” Jason Bergstrom emphatically answers. And he ought to know. Bergstrom is the go-to-market smart factory leader for Deloitte Consulting. (He has also attained a Lean Six Sigma Master Black Belt certification, so he knows more than a little something about manufacturing efficiencies.)

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the workforce into a cadre of people freshly graduated from a community college or a four-year program who come in to take care of operations – and it isn’t giving veteran employees a severance package. Tribal Knowledge “Most manufacturing jobs have technical components and functional knowledge-based, tribal knowledge-based components that you just can’t get rid of,” Bergstrom points out. In other words, long-term employees simply know how things are done to get product out the door. This know-how is important. While there is much to be said for “big data” in terms of compiling and processing information, there is still lots to be said for what Sally or Joe know about the operations they’ve been performing for many years. This isn’t something that is written down in a spreadsheet somewhere but what has become intrinsic knowledge. Should they be shown the door, that goes with them. Bergstrom says, “That knowledge is critical to products and services.” A driver that organizations of all sizes need to take into account is something that was made most evident by the COVID-19 pandemic and subsequent supply chain problems: “Whether it is onshoring or near-shoring, there is a need now

The Accelerating Transition Bergstrom believes the transition is one where traditional manual labor operations are being increasingly replaced by automation, whether with robots or smarter conveyance devices. Consequently, there is a need for the upskilling of individuals who will be taking on different roles within the operation and doing things like keeping the automation up and running. This is going to be a transition that is not going to happen overnight but which will take some time as people are trained – many on the job – in order to take on these new roles. Whether you are big or small, the kinds of folks who are going to be running your operations are going to start to look different. “Whether you are big or small, the kinds of folks who are going to be running your operations are going to start to look different,” Bergstrom says. However, there is something that Bergstrom underlines as being absolutely essential in terms of the transformation of

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for manufacturing to be close to the consumption point of the product.” This is not just something for large operations but even for Tier 2 and Tier 3 suppliers to major corporations. A key factor that this provides, Bergstrom says, is resiliency – to which smart manufacturing can contribute. In recent years, the sourcing decisions of many manufacturing companies were largely predicated on labor arbitrage: where the lowest cost can be achieved. This is why there are so many components and products shipped from Asia. Does Bergstrom think U.S. operations can be as competitive as those in places like Southeast Asia? “I absolutely do.” He adds: “You have to define ‘competitive’ differently.” Beyond Per-Unit Cost Bergstrom says that “competitive” was historically defined as the “per-unit cost.” “That is the wrong definition. If that is your definition, then it is likely your products are sitting in 40-foot containers off of Long Beach right now.” Yes, he says, cost is an important factor. But there is the resiliency factor, too: “You have to look across your supply portfolio. What are the choices you can make to assure a certain service level at a certain cost?” Let’s take the proverbial widget. Let’s say it can be produced in a country like Vietnam for 3 cents and 10 cents in North America. Historically, the decision would be made to have all the widgets produced in Vietnam. But let’s say that because of the deployment of smart manufacturing technology, an operation that is either based in North America or near-shore can produce the widget for 5 cents. So, Bergstrom says that a company can build a portfolio with half its widget supply based in Vietnam and the other half from a domestic or near-domestic operation. “Now you have a resilient supply of product at 4 cents rather than 3 cents. You may be taking a cost hit, but you’re doing it in a way that probably quadruples your resilience to market shock.” He adds: “I would say it only works if you’re paired up with smart manufacturing.” New Tech for New Tech According to the American Automotive Policy Council (AAPC), “automakers and their suppliers are America’s largest manufacturing sector, responsible for 3% of America’s GDP. No

other manufacturing sector generates as many American jobs. Not only are they America’s largest exporters, they also buy hundreds of billions of dollars worth of American steel, glass, rubber, iron, and semiconductors each year.” Which means U.S.-based automakers and suppliers make a lot of products and buy a lot of products to make those utility vehicles, trucks, and cars. Presently, GM is investing $35 billion in the development of electric and autonomous vehicles. It started the spend in 2020 and will complete by 2025. Ford recently announced that it is spending $50 billion on electric and other vehicle technologies by 2026. Those AAPC stats didn’t take numbers like these into account because this is a space that is changing rapidly. The point is that there are hundreds of suppliers that are going to be affected by this transition from 100% internal combustion engines (ICEs) to propulsion systems that are either all-electric or significantly electrified (i.e., hybrids). So, what happens to one’s business if it has been 100% dependent on ICEs? It is significantly downsized – or completely downsized – unless there is a transition to producing something else. Bergstrom points out: “Depending on how close the new product is to the one you’re making, you do have more agility with the smart factory.” Having advanced tech in place and an upskilled workforce won’t mean the transition to producing for the electrified auto industry will be easy – but it will mean that it will be easier than it would be otherwise. Time Compression To pull the focus out to encompass other industries, Bergstrom says that they’re seeing a compression in the amount of time that companies are taking to transition to smart manufacturing – regardless of the size of the company. “There used to be a large amount of time between early adopters and call it your ‘second tranche’ of followers. That’s no longer happening.” He adds, pointedly, “The lion’s share in tranche two or three have had their time compressed – they can’t afford to wait. The pandemic has driven a lot of this, and a lot of it is about supply chain. “They’re having to really accelerate their thoughts about digitizing operations in order to be successful.” He sums it quite succinctly: “Time is of the essence to compete and be successful.”

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

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THE BIG PICTURE

JOB SHOPS BY THE NUM

Trends in the United States

MOVEMENT FROM CITIES Job Shops , which were once concentrated around major urban areas with clustered customer industries, have been spreading out into suburbs and more rural areas over the last two decades. The most dramatic example is in Los Angeles County, California, where the number of shops has dropped dramatically , and the e ects can be seen as far away as Arizona and Utah. To a lesser degree, the same pattern is cropping up around Seattle with the aerospace industry, Houston with energy extraction and transport, and Detroit with automotive.

The reduction of shops in Los Angeles County demonstrates the migration of shops from urban to suburban areas.

THE MATERIALS The top ten metals machined by job shops are aluminum (1), stainless steel (2), mild steels (3), brass (4), tool steel (5), bronze (6), high-temperature alloys (7), copper (8), titanium (9), and cast iron (10).

THE MARKETS Aerospace is the single biggest market for job shops , at 56% , followed by machinery/equipment manufacturing at 49%. Military is the third-most served industry segment, at 44%. Automotive and medical are both at 39%, closely followed by oil and gas-fired mining machinery at 36%. * * Job shops likely work for many di erent industries and make parts of di erent sizes, so the numbers add up to more than 100.

MBERS

56%

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44%

TRIVIA 58% of job shops report performing lights-out and unattended machining.

39%

With regard to types of equipment, vertical dominates for rotational tools. 89% of shops report having vertical machining centers (VMCs), and horizontal for rotational workpieces, and 77% report having horizontal turning centers (HTCs).

36%

Sources: Chris Chidzik, Research and Survey Manager, AMT – The Association For Manufacturing Technology; Jan Schafer, Director of Market Research, Gardner Business Media; Kylea Dolezal, Market Research Assistant, Gardner Business Media; Gary S. Vasilash, Transportation Editor, Gardner Business Media

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

DIGITAL MANUFACTURING. IMPLEMENTED.

CO-OWNERS, ARC EDM INC. Ashley and Daniel love manufacturing because job shops like theirs make a little piece of everything. “We go to IMTS so we can be rock stars for our customers. They trust we’ll have the latest EDM technology to run their parts.” Find Ashley and Daniel at IMTS 2022.

GET TO KNOW ASHLEY AND DANIEL MILLER

VISIT IMTS.COM/ASHLEYDANIEL

IMTS

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Why Is IMTS 2022 the Place for Job Shops? BY PETER EELMAN CHIEF EXPERIENCE OFFICER

In North America, industries ranging from automotive and aerospace to agriculture, construction, and medical depend on job shops because the parts they make are in everything

metrology. Just as CNC manufacturers will debut “robot-ready” machining centers, quality assurance exhibitors are making sure that their measurement machines can communicate with robots to enable automated part load/unload to improve product iv it y. Metrology exhibitors are unveiling a host of new products to optimize workf low, improve manufacturability, and increase quality. Advances in CAD-CAM software and simulation are empowering manufacturers to be even more productive by simplifying CNC operations. The digital twin in CAD-CAM and simulation software is driving change by streamlining work for programmers and machinists alike. As a solutions-based show for a solutions-based industry, dozens of more products will be on display for tooling, workholding, abrasive machining, fabr icat ing, gear generation, and cleaning. Practical Learning and Networking The IMTS Specialty Program: Job Shops featuring MMS Top Shops is exclusively designed to offer job shop stakeholders learning opportunities to excel, connect, and manufacture. This program offers keynote speakers, industry panel sessions, roundtable discussions, top shops data, benchmarking metrics, and industry outlooks. It also includes special workshops on how job shops can incorporate additive manufacturing and information on the supply chain. Find solutions from industry experts and your peers. See It All at IMTS 2022 From Sept. 12-17, job shop owners, managers, and their employees can experience the incredible advances in manufacturing that can lead to new levels of efficiencies and prosperity, gain insight from industry experts, and expand their networks to form new partnerships. I urge you to register now at IMTS.com/register. Your customers, their customers, your suppliers, your employees, your family – everyone depends on you. You make things happen. You buy efficiently, invest wisely, sell fairly, and make reasonable profits. Sometimes, to be effective, you need to step away from the pressure of day-to day doing and immerse yourself in innovative possibilities. IMTS is where you can dream big about the “what ifs” and set the stage for the future of your business success.

we use. Year after year, our data reveals that 15% of IMTS visitors are from job shops or contract manufacturers – the vital backbone of manufacturing. In recognition of the importance of job shops and small manufacturing businesses, IMTS is committed to making the show a valuable experience for job shop owners and the people who work in them. IMTS 2022 offers job shop stakeholders the technology, new products, practical learning, and networking opportunities that will grow their businesses and profit margins, make them more resilient, and help them adapt to changing markets and workforce challenges. Technology and New Products Digital manufacturing will be prominent throughout IMTS 2022, thanks to the technologies that bridge the gap between the digital and physical. As job shops contend with workforce and supply challenges to compete globally, they are aggressively adopting digital manufacturing processes and products, which are encapsulated within traditional machines that use automation and robotics, additive manufacturing, metrology, augmented and virtual reality, digital twin, generative design, and more. Exhibitors will be showing off plenty of augmented CNC machines with digitally connected automation and robotics systems to enable a new generation of multi-tasking machines. Another trend in CNC systems is the single-setup concept. Multi-tasking machines combine cutting with turning, milling, drilling, tapping, deep-hole boring, hobbing, skiving, broaching, grinding, and surface preparation. Hybrid multi-tasking machines add laser hybrid, friction stir welding, additive, and hot wire EDM. By performing all work in a single clamping, these machines cut setup time, eliminate the risk of losing zero when parts move between workstations, and free operators to perform other tasks. One of the fastest growing segments in automation is cobots. Companies that once never considered robotic automation are now adopting cobots in their operations because today’s cobots are very simple to operate and can handle a wide variety of tasks that were previously impossible. Technological advances have contributed to their growing popularity, improving ease of use and increasing their flexibility to do many jobs around the shop. The explosive growth seen in automation also extends to

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

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Printing Proof: ‘FutureView’ on IMTS+ BY MICHELLE EDMONSON SENIOR DIRECTOR, EVENTS & CONTENT

aims to improve the competitiveness of U.S. manufacturers while reducing their carbon footprint. Over the course of four episodes, “FutureView” introduces viewers to the people behind the machines at the MDF. In the first episode, the folks at the MDF take their very own moonshot, using the Big Area Additive Manufacturing machine to 3D print concrete molds to build machine tool bases. These molds are affordable, reusable, and can incorporate sensors. We learn about the “secret sauce” of the MDF in the second episode, which involves gathering a lot of smart people and

The future of additive manufacturing is taking shape layer by layer at the Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory. “FutureView,” brought to

you by ZEISS Industrial Quality Solutions, is an IMTS+ Network Original Series that documents the development of technologies at the MDF that could revolutionize the manufacturing industry. A unique collaboration between government, industry, and academia developed by the Department of Energy, the MDF

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The future of additive manufacturing is taking shape layer by layer at the Manufacturing Demonstration Facility at Oak Ridge National Laboratory. FutureView documents the development of technologies at the MDF that could revolutionize the manufacturing industry. Stream FutureView Season 1 on IMTS.com and get to know the people behind the machines at the MDF. Find FutureView and other binge-worthy premium content, exclusive interviews, and stories covering the human side of manufacturing on IMTS+.

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establishing a truly collaborative environment. The proof is in the fact that the facility can go from ideas to real printed parts in days – not years. To truly use additive manufacturing at a large scale in industries that demand precision, every printed part has to be meticulously measured. The third episode focuses on the MDF’s partnership with ZEISS Industrial Quality Solutions to implement innovative CT scans of parts so they can be examined at the nano level – ensuring perfection you can’t see but absolutely need when it matters most, like in a nuclear reactor. Finally, in the fourth episode, the MDF details its efforts to develop new methods for printing solar turbines for energy

production. Using 3D printing, the facility is compressing design time, allowing them to efficiently try new designs and materials until they get it right. “Getting it right” means more efficient, cleaner energy production. Continue to explore IMTS+, a new digital destination showcasing the people, connections, and inspirations of our community. You’re invited to this dynamic content platform to watch, read, and join the events and stories that drive the modern manufacturing industry. Start your journey today when you register at IMTS.com/IMTSplus.

For questions about IMTS+, contact Michelle Edmonson at medmonson@ AMTonline.org.

Join Modern Machine Shop in exploring the challenges facing American manufacturing. Through exclusive commentary from world class economists and manufacturing leaders, we shine a spotlight on the past, present and future of being made in the U.S.A.

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Job Shops by the Numbers A look at what some of the job shops in the United States are doing. BY JAN SCHAFER DIRECTOR OF MARKET RESEARCH, GARDNER BUSINESS MEDIA Think about a franchise business such as one of the multitudinous fast-food operations. You could buy a hamburger at one outlet in Portland, Maine, and a burger at another in Portland, Oregon, and they are almost exactly the same. The tools and the methods are standardized. Job shops aren’t like that. Each is its own thing. Each does things differently. But there are some commonalities.

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(26%), 48-inch (16%), and >48-inch (15%). This shows a pattern of larger sizes being less commonly addressed by job shops. These businesses, which are mainly independent job shops (48%), followed by contract shops (40%) and captive shops (11%), service an array of industries. The Markets Aerospace is the single biggest market, at 56%. This is followed by machinery/equipment manufacturing at 49%. Military is the third-most served industry segment, at 44%. (Remember: As these are job shops, they likely work for many different industries and make parts of different sizes, so the numbers add up to more than 100.) Automotive and medical are both at 39%, closely followed by oil-and-gas-fired mining machinery at 36%. As industries served follows demand, it is a fairly safe supposition that because of exogenous conditions – from the war in Ukraine to the pandemic to the global energy supply to the electrification of the auto fleet – these top six markets are likely to not only remain at the top but increase as a percentage of business. (Perhaps something of a talking point – or a bit of interesting trivia – is the industry with the least amount of business for the job shops: furniture manufacturing, at 6%. Given the increase of remote work or hybrid situations and reduced in-office hours, the demand for office furniture is not likely to grow.) It is worth knowing that when it comes to customers, these facilities evidently do an exemplary job: the customer retention rate is 98%. The Equipment With regard to types of equipment, vertical dominates for rotational tools, with 89% reporting having vertical machining centers (VMCs), and horizontal for rotational workpieces, with 77% having horizontal turning centers (HTCs).

Gardner Business Intelligence has surveyedmore than 400 job shops across the United States as part of Modern Machine Shop’s Top Shops benchmarking program. The “Top Shops” are the top 20% of the participants, scored on 14 metrics. What follows is a numeric look at what we’ve found. Please keep in mind that: • The percentages cited are median numbers. • None of these things necessarily make any given firm a Top Shop – but it probably wouldn’t hurt to consider what these numbers show and compare it with your operation. • For the most part, this is what is happening at independent operations, not cookie-cutter franchises. Results may vary.

What They Are; What They Do

IMPROVEMENT METHODOLOGIES BEING IMPLEMENTED BY JOB SHOPS

100%

80%

60%

40%

20%

0%

Cellular Manufacturing

Some Improvement

5S Workplace Organization

Benchmarking

Lean Manufacturing

Top Shops have a median batch size of 95 parts. These parts generally fall within a 6-inch cube (65%) and a tolerance of 0.0005 inch (40%). One interesting thing to note on the subject of tolerances is that 0.0001 inch is actually a fairly common spec, as it is reported by 33%, which makes it the second most common tolerance.

Going back to the cubic dimensions, following the 6-inch cube are the following cubic sizes: 12-inch (56%), 18-inch (45%), 24-inch (35%), 36-inch

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The Materials As previously mentioned, aerospace is the leading industry served, which probably goes to the point that 95% report machining aluminum. Additionally, primarily in aero, high temperature alloys (58%) and titanium (53%) are among the materials most processed by the shops, as they are seventh and ninth in the top 10. Rounding out the top 10 of metals machined are stainless steel (2), mild steels (3), brass (4), tool steel (5), bronze (6), copper (8), and cast iron (10). Only cast iron is below 50%, at 46%. The Personnel When it comes to skilled staff, only 18% reported that they have no shortage. Of those firms, they took a variety of approaches to address the shortage, with the predominant strategy being cross-training (80%). In terms of improvement methodologies being undertaken by these shops, the numbers are somewhat low. Fifty-three percent say that theyhave some continuous improvement activity. But then the numbers fall, with 42%performing 5S workplace organization, 32% benchmarking, and 30% cellular manufacturing. At the very bottom is lean manufacturing (5%), which arguably means that there are some huge opportunities for some shops to improve their operational fitness. This article was written by Jan Schafer, Kylea Dolezal, and Gary S. Vasilash. To learn more about “Top Shops” identified by Modern Machine Shop, attend the Job Shops Program at IMTS 2022. For details, visit IMTS.com.

Although CNC machines have been commercially available for more than 50 years, the types of machines that tie for third in terms of being on shop floors are lathes and milling machines – without CNC – at 62%. They are followed by horizontal machining centers (HMCs) at 58%. Taking the number of VMCs, HTCs, and HMCs into account, the dominance of CNC is clear. The median number of CNC machine tools is 16, with an age of seven years. What’s more, 86% of respondents report having CAM software (and 88% CAD), so these shops are well into CNC operations. Additionally, 58% respond that they perform lights-out and unattended machining, so it is clear that computer control is part of their operational regime. While it isn’t entirely surprising that plasma/oxy-fuel machines come in second from the bottom at 7% – after all, these shops are more concentrated on machining so there isn’t a whole lot of plate cutting occurring – what is somewhat surprising is that at the bottom, at 5%, are twin-turret machines. This could be a function of twin-spindle machines lending themselves to volume production and so are probably perceived to be insufficiently flexible for job shop applications. components, there is something of a dearth, with 9% reporting having the equipment. Still, there are 68% of the shops not using 3D printing at all. In the inspection arena, there is something that is both surprising and expected in the top spot for equipment: optical comparators, at 73%. This is surprising because compared to the coordinate measuring machine (CMM), which is in the second spot at 69% (these CMMs are in a quality department; shop floor CMMs are back in sixth place at 27%, ahead of a portable measuring arm at 24%; nothing is last, but still 6%), the optical comparator is a tech that’s been around for 100 years – which is not to say that it hasn’t been improved in that time. Its ranking is not surprising because when it comes to speed and flexibility, they are highly useful tools. One technology that has room for growth in the job shop arena is 3D printing, or additive manufacturing. Only 32% report they use the technology. Of that number, 60% are using desktop units for printing polymer materials. Stand alone machines, with more substantial work envelopes, are at 39%. However, when it comes to additively building metal components, there is something of a dearth, with 9% reporting having the equipment. Still, there are 68% of the shops not using 3D printing at all. However, when it comes to additively building metal

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