In a recent interview on Universal Robots’ “Reanimated” podcast, Rozier and Kobayashi shared their insights on the critical role of education in preparing the next generation of manufacturing professionals.

Rozier, the Director of Digital Advanced Technology and Robotics for Festo Didactic North America, has a unique perspective on this challenge, having spent 18 years as a system integrator before transitioning to the education space. “When I got the opportunity to join Festo and bring that 18 years of experience into the classroom, I realized that there was more to it than just putting the emerging technology in front of the students,” he explained. “Part of that full-blown turnkey solution is the curriculum.”

This sentiment is echoed by Kobayashi, who is the Global Industry Segment Manager for Education at Universal Robots. She too recognized the importance of curriculum and content development when she first started working on education programs while at Zeiss, a leading manufacturer of optical and optoelectronic systems.

“I actually sat down and built educational curriculum and content based off of our industrial training materials that we had, that could go and be used by schools for teaching,” Kobayashi said. “I could really resonate with what Ted said about content being king.”

The emphasis on content and curriculum is critical, as it goes beyond simply providing the technology and equipment. It’s about ensuring that students not only have hands-on experience with the latest tools and systems, but also a deep understanding of the underlying principles and concepts.

“When we speak specifically to the project that we’ve worked on together with the robot safety training cart, something that I love about that is that in working with different schools, when they pull the product out the box, they want to know how do I get started,” Rozier explained. “They don’t want to know about theory. They want, you need to be able to show what it does.”

Kobayashi echoed this sentiment, highlighting the importance of creating a comprehensive learning experience that combines theory, interactive lessons, hands-on activities, and knowledge checks. “We’ve got an amazing e-learning platform. It’s actually free on Universal Robots Academy. And you can go in and you can actually start programming through an interactive e-learning interface without a robot, without anything next to you. So really just start to get a feel for how this is going to work.”

But the learning journey doesn’t stop there. Rozier emphasized the significance of certification, noting that it serves as a critical bridge between education and industry. “When a student goes to get a job, how is he interviewed? And if you can show me a certificate that you have specific skill sets, I know how to query you to see if you know what you’re talking about. Without the certificate, I have to start from scratch.”

This focus on certification is not just about validating the student’s knowledge, but also about ensuring that the curriculum and content are truly aligned with the needs of industry. “Curriculum is the gas to certification. You can’t certify unless you’ve done a good job on the curriculum side. If you do it the opposite, it’s not going to be stackable,” Rozier explained.

The partnership between Festo Didactic and Universal Robots is a prime example of how industry and academia can collaborate to create robust, industry-aligned educational programs. By integrating Universal Robots’ collaborative technology into Festo’s “Manufacturing Production System” (MPS) training cart, they’ve developed a comprehensive learning platform that goes beyond just teaching the basics of robotics.

“That cart attaches to approximately 10 other modules. And that’s why it’s a great transition from the core into the systems approach, because now you’re not only building a part, but it’s going to be processed,” Rozier said. “So that student, not only do they understand or get a chance to learn about safety that’s integrated into that system, but functional safety. What does it mean to the whole system?”

Kobayashi emphasized the importance of this systems-level approach, noting that robots rarely operate in isolation in the real world. “Robots are never working alone on a production floor. Anyone who’s worked with robotics knows that. And while it’s really important to get a base understanding of operation with robotics, which universal robots curriculum and hardware set is a really great place to start with that. Students really need that real-world exposure to other elements, to PLC, to really understand how robots communicate and interact with other peripheral equipment.”

This holistic approach to education, integrating theory, hands-on practice, and real-world systems thinking, is a testament to the collaborative efforts of Festo and Universal Robots. But it’s not without its challenges, as Rozier pointed out.

“The hardest part, I would say, when it comes to, we’ll speak to emerging technology and some of the buzz out there, Industry 4.0. Okay. When you talk about our communication architecture, sometimes you want to walk in the classroom and you want to hit the easy go button. Okay. A tightly integrated system, when everything is aligned and it’s put together, it runs like a champ. But there are issues come up within our cyber physical platform and manufacturer production system.”

To address these challenges, Festo has incorporated an “Overall Equipment Effectiveness” (OEE) platform, which adds an additional layer of complexity to the learning experience. “It takes the student and makes it where they’re not just working on or troubleshooting electrical, mechanical, IELTS software. But big picture, what does the CEO care about in a manufacturing plant? Throughput. So, when you start to integrate all of that technology, try and slow everyone down and get them to understand each layer. It does take a little more time.”

But the payoff is worth it, as Rozier and Kobayashi both believe that this holistic, industry-aligned approach to education is crucial in bridging the skills gap and preparing the workforce of the future.

“Employability. We’ve seen students go through and they’re able to walk into a manufacturing plant and they’re able to read the program,” Rozier said. “They should be able to read that story, just like they went to their new employer. They walk in that manufacturing plant up to the line, whatever it is, they’re going to grab the program and they should be able to read it.”

Kobayashi echoed this sentiment, emphasizing the value that these educational programs bring to both students and employers. “That tells future employers that this student understands these skills and these competencies and has this level of understanding on a specific topic, whether that be mechatronics, industry 4.0, robotics. So really brings a lot of value, I would say, both to students, but then also to those future employers that they can understand where students are understanding is and what their specializations are.”

As the manufacturing landscape continues to evolve, the importance of bridging the skills gap through innovative and industry-aligned educational programs cannot be overstated. Rozier and Kobayashi’s work at Festo Didactic and Universal Robots, respectively, serves as a shining example of how industry and academia can collaborate to elevate the future of automation and manufacturing.

“It’s one of the things that really excites me. How can you demystify emerging technology methods in the classroom?” Rozier said. “Being able to bring smart manufacturing into the education space is extremely exciting. It’s what gets me up every morning.”

By prioritizing content, curriculum, and industry-relevant certification, while also embracing a systems-level approach to learning, Festo and Universal Robots are paving the way for a new generation of manufacturing professionals who are equipped to thrive in the ever-changing landscape of automation and Industry 4.0. This collaborative effort serves as a model for how industry and academia can work together to address the skills gap and ensure the long-term success of the manufacturing sector.

The post Elevating Automation Through Education: Bridging the Skills Gap with Industry and Academia appeared first on IndMacDig | Industrial Machinery Digest.

A Legacy of Excellence: Meet Rick Arcaro

With 27 years at HYDMECH and nearly four decades in the industry, Rick embodies the company’s dedication and expertise. “I’ve been with the company since 1986, and it’s only the third job I’ve ever had. It’s a great industry—addictive, really. You get to see new stuff every single day; you’re never stale,” he shared enthusiastically.

Rick’s long tenure at HYDMECH underscores the company’s stable and nurturing work environment. “Working for HYDMECH is fantastic because we’re not a stale company. We’re very progressive, innovative, and just a great place to work. We have a lot of good people,” he added, highlighting the company’s strong internal culture and commitment to employee satisfaction.

What Sets HYDMECH Apart?

When asked about what distinguishes HYDMECH’s products from competitors, Rick provided a comprehensive overview. “Our machines are bar none the easiest to run in the industry,” he stated confidently. This ease of operation is a significant differentiator in a market where labor shortages and the need for efficient training are pressing concerns.

One of HYDMECH’s standout features is their user-friendly interface. “We’re the only machine tool builder that actually gives you a directions door chart in our PLC on our machine, how to run it. So if your operator’s not there today, somebody can come over and be a saw operator and keep your production going.” This level of accessibility ensures that even less experienced operators can manage the machinery effectively, minimizing downtime and maintaining productivity.

Rick also emphasized the practicality of HYDMECH machines in terms of maintenance and part replacement. “Our machines are built with a lot of common components. Anything on a saw that we don’t machine, weld or fab, you can buy at a local supply house. So supply chain issues, replacement parts are very simplistic on HYDMECH machines.” This approach not only reduces operational costs but also enhances the reliability and longevity of their equipment.

Driving Innovation in a Changing Market

Innovation remains at the core of HYDMECH’s strategy. “Keeping up with the market, one thing coming out of COVID taught a lot of people, how to deal with supply chain, but more so how to deal with labor and I believe more the lack of labor,” Rick explained. The pandemic highlighted the vulnerabilities in global supply chains and exacerbated the existing labor shortages, prompting companies like HYDMECH to adapt and innovate.

To address these challenges, HYDMECH focuses on making their machines as easy and simple to operate as possible. “Our machines have to be easy, simple, and non-intimidating to run. So that basically, again, distinguishes us from some of the other competitors” Rick noted. This user-centric design philosophy ensures that businesses can maintain high production levels even with a limited pool of skilled labor.

Rick highlighted several key innovations in HYDMECH’s new product line. “The innovations we have are easier to operate than they were 10 years ago, 15 years ago. Our production levels are higher. A lot of that’s due to components on machines. In fairness to our market, a lot of it’s due to the blades. We build the machine, we don’t build the blades. The innovation of blades have come a long way in the last 10 years as well.”

Furthermore, HYDMECH is expanding its reach into automation. “We sell automation daily. The sawing market has now held a bit of a different standard. 10, 12 years ago, “a saw is a saw”. Now they’re referred to as machine tools. And it’s a big difference. And you’ve got people buying high-end sheer press brakes and lasers, and now our machines are going next to them.” This shift signifies HYDMECH’s commitment to integrating advanced technologies that align with the evolving demands of modern manufacturing.

Targeting a Diverse Market

HYDMECH’s versatility is a key strength, allowing them to cater to a broad spectrum of industries. “HYDMECH for a lot of years has always been a leader in fabrication. A lot of our machines have the capability to miter cut angles, shapes, products. That’s where the business started. The owner of the company was the innovator of the first bandsaw machine where the head moved instead of the material,” Rick recounted.

The company’s flagship machine, the S-20, stands as a testament to their innovative spirit. “If you go out and Google an S-20, it’s the highly most recognized machine name and brand in the world. It’s the most copied machine name and brand in the world. So that’s got to be some sort of flattery. We must be doing something right.”

Over the years, HYDMECH has expanded its capabilities beyond fabrication to compete in the chip market. “We’ve developed a much better standard of just straight cutting for the chip industry. Where we hung our hat in fabrication, we’ve certainly now compete daily in the chip market. So we’ve become a very large Swiss Army knife type company that we can walk into the small two-person machine shop to the service centers of automotive plants, forgers that may be employing 300 people. We fit all market segments,” Rick elaborated.

This adaptability ensures that HYDMECH can serve a wide range of clients, from small businesses to large industrial operations, providing tailored solutions that meet their specific needs.

Commitment to Quality and Sustainability

HYDMECH’s commitment to quality is evident in every aspect of their operations. “Quality is at the core of HYDMECH’s operations. We adhere to stringent quality control processes and hold various certifications, including ISO 9001 and ISO 14001,” Rick emphasized.

Moreover, HYDMECH is dedicated to sustainable practices and corporate social responsibility. “We implement eco-friendly manufacturing processes, minimize waste, and strive to reduce our carbon footprint. Additionally, HYDMECH engages in community initiatives and supports various social causes, reinforcing our role as a responsible corporate citizen,” Rick highlighted.

This holistic approach not only enhances the company’s reputation but also aligns with the growing emphasis on sustainability within the manufacturing sector.

Global Reach and Exceptional Customer Support

With a global footprint, HYDMECH ensures that its products are accessible to customers worldwide. “We serve customers across different continents, ensuring that our products are accessible wherever needed,” Rick stated. “We pride ourselves on providing excellent customer support, offering technical assistance, maintenance services, and training to ensure optimal performance of our products in the field,” Rick added.

This comprehensive support system ensures that customers can maximize the efficiency and longevity of their HYDMECH machinery, fostering long-term partnerships and customer loyalty.

Promotions and Future Outlook

As FABTECH 2024 closed, HYDMECH is keen on maintaining its momentum. “HYDMECH’s offering a package on our machines. From now until mid-December, we’re offering a 7% discount on several of our machines and accessories and packages. So we’re looking to keep our backlog moving,” Rick announced.

However, the company is experiencing high demand, with bookings already filling into early 2025. “One challenge for us is we’re already booking into 2025 Q1, unfortunately some Q2. We’ve had a very good year and I’m certainly not going to apologize for that for lead times, but it’s a challenge. I still got to give somebody an incentive to wait for a HYDMECH because there are other choices out there. So I believe we’re worth the wait,” Rick assured.

This robust demand reflects HYDMECH’s strong market position and the trust that customers place in their products. The company’s ability to consistently deliver high-quality, reliable machinery ensures that it remains a preferred choice in a competitive landscape.

Looking Ahead

As the manufacturing landscape continues to evolve, HYDMECH remains poised to lead with innovation and adaptability. Rick Arcaro’s insights at FABTECH 2024 revealed a company that not only honors its rich legacy but also embraces the future with cutting-edge technology and a customer-centric approach.

“HYDMECH is a unique company in that area,” Rick concluded. “We strive to reduce material handling, optimize processing, and give operators the tools they need to run multiple machines efficiently. This focus on innovation and efficiency sets us apart and ensures that we continue to meet the diverse needs of our customers.”

With its unwavering commitment to quality, innovation, and customer satisfaction, HYDMECH is well-positioned to navigate the challenges of the modern manufacturing industry and continue its trajectory of success.

The post HYDMECH Shines at FABTECH 2024: Innovations and Industry Insights from VP Rick Arcaro appeared first on IndMacDig | Industrial Machinery Digest.

Why Ball Pins Demand Precision

Ball pins, typically found in automotive steering systems and chassis, are essential to a vehicle’s operation, allowing movement and flexibility between different parts while enduring constant physical stress. Given their role in vehicle safety, ball pins must meet stringent quality requirements with no margin for error, down to micrometer-level tolerances. EMAG’s VST 50 was developed with this goal in mind, focusing on creating an ultra-efficient, automated system that maintains uncompromised precision in every machined component.

Engineering and Automation Innovations

EMAG’s development team took a unique approach to designing the VST 50, integrating three independent robots to optimize productivity and achieve the sub-two-second chip-to-chip time that defines the machine’s performance. The setup includes dual suspended workpiece spindles, which enable simultaneous loading, unloading, and machining to maintain a seamless workflow. One spindle is loaded and unloaded while the other actively machines the ball pin, maximizing operational efficiency and enabling continuous production.

Advanced Tooling Capabilities

Tooling on the VST 50 is meticulously designed to achieve the high precision required for both the ball and neck of each pin. On the machine’s left side, a rotary B-axis provides precision for machining the ball, supported by a linear U-axis to adjust the ball diameter and shape. On the right side, specialized tools manage the neck machining, completing a process tailored to meet demanding surface quality and dimensional specifications. This arrangement enables the VST 50 to handle both short and long ball pins, with diameters from 16 to 40 mm and lengths between 50 and 455 mm.

Integrated Robots for High-Productivity Loading and Tool Changing

Rather than relying on a single robot for multiple tasks, EMAG chose a three-robot system, each responsible for specific tasks in the VST 50’s production line. The left and middle robots transfer workpieces to each spindle, while the third robot manages additional automation tasks outside the immediate machining area. This layout allows simultaneous movements, supporting the VST 50’s rapid cycle time and ensuring consistent, high-speed output.

The integrated robots also streamline the tool-changing process. Operators receive automated notifications on the machine’s central control panel when a tool change is necessary. With the press of a button, the tool magazine swings out for easy access, allowing the operator to change tools without disrupting production. Once the new tool is in place, the robot handles the actual tool replacement within the machine, ensuring minimal downtime and enhanced process reliability.

Precision Control and Quality Assurance

For a component as critical as a ball pin, achieving flawless production quality is essential. To ensure each component meets required specifications, the VST 50 includes a high-resolution light band micrometer that measures both the ball and neck diameters instantly, flagging any deviations from the intended design. This real-time quality control allows manufacturers to maintain stringent standards, reducing waste and rework. Additionally, a process camera positioned at the machine’s loading point provides live images on the control panel, enabling operators to detect and resolve any issues immediately.

The Role of EDNA Apps in User-Friendly Operation

To further enhance efficiency, EMAG equips the VST 50 with its EDNA app ecosystem. This digital interface simplifies machine operation, integrating control of the robots and measurement tools, and enabling intuitive interactions. Operators can seamlessly manage production parameters and monitor real-time performance metrics, making the VST 50 as user-friendly as it is efficient. The EDNA apps support a range of production needs, including tool management, quality control, and predictive maintenance, ensuring the machine remains operational with minimal downtime.

Versatile Applications Beyond Ball Pins

While the VST 50 is designed primarily for automotive ball pins, EMAG sees potential for its application in other industries that require high-precision machining of small, durable parts. The machine’s flexibility to work with ball pins of various sizes—as well as its capacity to machine ball sleeves—makes it an attractive solution for manufacturers across multiple sectors. EMAG estimates the VST 50 to be twice as fast as comparable production solutions, significantly reducing unit production costs and offering a competitive advantage.

EMAG’s Vision for the Future of Component Production

According to Frank Haas, project manager and development engineer at EMAG, the VST 50 is a game-changer for ball pin production. “We’re taking the production of ball pins to a new level,” says Haas. “With the VST 50, we can meet the automotive industry’s stringent demands for quality and precision, while also delivering on speed and efficiency.” EMAG’s commitment to innovation is evident in every aspect of the VST 50’s design, from the advanced robotics to the EDNA-powered digital interface, making it a versatile and reliable solution for high-demand manufacturing.

As industries worldwide strive for increased efficiency and cost-effectiveness, EMAG’s VST 50 sets a new benchmark in automated component production. This machine not only meets current production needs but anticipates future demands for higher precision, faster throughput, and integrated digital control. With the VST 50, EMAG continues to pave the way for advancements in manufacturing technology.

The post EMAG Introduces VST 50: Revolutionizing High-Speed, High-Precision Ball Pin Production appeared first on IndMacDig | Industrial Machinery Digest.

ComGroup’s 2025 Industrial Marketing Trends report draws from the agency’s annual research, industry insights, and more than 30 years of experience working with a diverse range of B2B and industrial clients—from small family-owned businesses to global industry leaders. This evolving report provides valuable insights for B2B and industrial professionals, helping them understand the evolving marketing landscape and guiding their strategic decisions for the year ahead. ComGroup’s Industrial Specialist and Agency Founder Dane Cowling says the report equips decision-makers with the tools they need to navigate the rapid evolution of technology and changes in consumer attitudes and behaviors.

“Advancements in technology, data analytics, and shifting consumer expectations will continue to shape the industrial marketing landscape beyond 2024,” Cowling said. “The future of industrial marketing will be defined by the rapid pace of these technological innovations, data-driven insights, and the constantly evolving demands of consumers.”

The 2025 Industrial Marketing Trends report is now available for download on the ComGroup website. Visitors can use the report’s insights to refine and enhance their own marketing and communication strategies, identifying areas that may need adjustments, amplification, or improvement. Additionally, ComGroup offers other online resources, such as a complimentary website audit and content suggestions, to help visitors assess and improve their current marketing and communication efforts.

About The Communications Group

The Communications Group is an award-winning, Arkansas-based, marketing and public relations firm established in 1987. ComGroup is an integrated marketing and communications firm delivering value and solutions to clients in North America and Europe with data-driven strategic research and planning, integrated technology-driven implementation and responsive monitoring in agriculture, business-to-business, health care and outreach and education sectors.

The post 7 Key Industrial Marketing Trends to Watch in 2025 appeared first on IndMacDig | Industrial Machinery Digest.

Particularly for engineering-heavy industrial equipment environments, these BOMs often have a very complex structure with multiple levels or layers of subassemblies. While the drawings in a CAD or design program handle this easily and natively, the way the full BOM for a top level, finished product is structured in an ERP/MRP system has significant impact on the production of the actual product. Production managers and shop floor workers have to navigate the complexities of a multi-level BOM in real-time as they keep to a production schedule and can get frustrated or overwhelmed dealing with an extraneous amount of paperwork or unnecessary data.

Building a bridge between engineering and production is crucial to maximizing quality without sacrificing efficiency.

Dividing a Manufactured Part into Sub-Parts

The first decision is how to structure the bill of materials within the business system used to run operations, typically an enterprise resource planning (ERP) system, and then determine whether to stick to the complex, hierarchical, sub-BOM (or subassembly) structure or to ‘flatten’ the BOM into a single-layered product.

Take the process of building a custom conveyor system as an example. You could either:

• Create a single BOM that includes the entire system, such as the frame, motor, and belts.
• Or divide it into subassemblies for the frame, motor, and belts, each of which is managed and produced separately before integrating during final assembly.

A flexible, manufacturing-focused ERP will allow for either approach and should provide options for simplifying production even with the complex, multi-level structure.

Either approach results in a functional product that effectively drives inventory, captures cost, and meets specifications. But, often a multi-level BOMs requires the ability to manage suborders and planning for each of the subassemblies, and your production plan and goals must be considered.

If a subassembly must be built discreetly (for traceability purposes), is overbuilt or purchased from a subcontract manufacturer, then the best practice is to maintain the subassembly breakout in a hierarchical BOM. If a subassembly is shared amongst other products in your mix, it is often more efficient to ‘overbuild’ or ‘batch’ build these subassemblies separately, maintaining some kind of safety stock, or building to a consolidated demand through material requirements planning (MRP).

If you are responsible for all production, and these subassemblies are unique to the top level, you will need to consider the implications of the complexity in production. Your production process may be most efficient by processing a flat BOM on a single work order that captures all raw material/component demand and labor for the entire product.

Understanding the Impact of Subassemblies on Production Efficiency

Once the bill of materials is structured within your ERP system, the process of initiating production begins when a work order is issued. A manufacturing ERP system will be capable of recognizing the relationships between subassemblies and the top-level BOM and should provide practical tools to streamline production workflows based on these connections.

A robust ERP, such as Cetec ERP, also offers manufacturers several options for handling subassemblies, ensuring that production planning aligns with operational efficiency and material availability. Typically, manufacturers can choose from the following options when managing sub-BOMs:

1. Create Suborders – discrete suborders under the parent order

This option triggers a work order for each subassembly, linking it to the parent work order. This would typically include tools for maintaining full oversight of the production stages for the entire project, allowing for real-time visibility and adjustments to the schedule and production status. This is particularly beneficial when all manufacturing is in-house and subject to complex, dynamic scheduling needs or traceability requirements.

2. Do Not Create Suborder – defers material planning downstream to an MRP

In cases where subassemblies are outsourced or frequently used across different products, this option allows manufacturers to bypass the creation of additional work orders. The subassembly is treated as a purchased component, simplifying the overall work order structure and allowing production planners to handle demand through MRP processes to consolidate demand for the subassembly and create a work order (or purchase order) only if necessary. This option minimizes disruptions by ensuring that purchased parts are available when needed without triggering unnecessary internal builds.

3. Phantom BOMs – flattens the BOM structure into a single work order

Phantom BOMs (or phantom assemblies) serve as a valuable solution when subassemblies are logically required by engineering for labor and/or materials but present unnecessary complexity during production. This option effectively combines the components, labor, and documents of a subassembly directly into the top-level BOM, treating the subassembly as part of the main product without generating separate work orders. By using phantom BOMs, manufacturers can maintain structured product hierarchies while simplifying the production flow.

Optimizing Sub-BOM Settings for Maximum Production Flow

To further optimize your production, your ERP system should be able to automate these decisions regarding subassembly builds based on real-time inventory levels. If sufficient stock is available for a particular subassembly, the system can automatically opt to not build, preventing unnecessary production orders. Conversely, when stock is low or unavailable, the system should be configurable to allow the switch to create suborders based on the determined shortage for the top-level by calculating the required quantities for production. This level of automation reduces manual intervention, ensuring that production schedules are not derailed by stock shortages or excess.

This approach also guarantees that subassemblies are created or bypassed based on material availability, which not only streamlines production but also optimizes resource allocation, minimizing production delays and material waste.

Leveraging Phantom BOMs for Enhanced Production Flexibility

Phantom BOMs offer a powerful alternative when standard subassembly structures create bottlenecks in production. By integrating subassemblies directly into the top-level BOM without generating separate work orders, manufacturers can simplify workflows without sacrificing structure or traceability.

Consider a scenario where a manufacturer is building an industrial HVAC system that includes several subassemblies such as the compressor, evaporator coil, and blower assembly. Instead of creating separate work orders for each of these components, a phantom BOM allows the manufacturer to group them into the main system’s BOM. The production team can then issue a single work order for the entire HVAC system, which includes all necessary materials for these subassemblies. This approach saves time, minimizes administrative overhead, streamlines the workflow, and ensures that production continues without unnecessary delays or interruptions.

Phantom BOMs preserve the logical relationships defined by engineers while providing the production team with a more straightforward, efficient method for assembling complex products. This flexibility is especially valuable in industries with high complexity, such as aerospace, medical devices, and automotive manufacturing, where product variations and customizations are frequent.

Important Advantages of Phantom BOMs

Phantom BOMs offer several practical benefits that can significantly transform production efficiency:

Reducing Administrative Load: By consolidating work orders, production workers are no longer overwhelmed by an excessive amount of paperwork related to multiple subassemblies. This streamlining allows teams to focus on actual assembly rather than administrative tasks.

Improving Material and Workflow Coordination: Phantom BOMs eliminate the need for sequential builds, enabling the assembly team to work on subassemblies as part of the main build process. This eliminates unnecessary stops in the workflow, keeping production moving at a faster, more efficient pace.

Enhancing Flexibility in the Production Line: By allowing subassemblies to be built along with the top-level assembly, phantom BOMs provide production teams with greater flexibility in scheduling and task prioritization. This adaptability is particularly important in environments where lead times are tight, or product variations are frequent.

Balancing Engineering Complexity and Production Efficiency

Manufacturing companies often find themselves trying to reconcile the detailed, structured approach required by engineering with the need for speed and efficiency on the production floor. Multi-level BOMs are essential for maintaining the integrity of complex product designs, but if not carefully managed, they can lead to slowdowns and inefficiencies in production.

By embracing best practices in BOM structuring, such as automating build decisions and utilizing phantom BOMs, manufacturers can keep both engineering and production teams aligned. A modern ERP system that supports these strategies will enable businesses to maintain detailed product structures while keeping production streamlined and flexible.

With the right tools and strategies, it’s possible to retain engineering precision without bogging down production with unnecessary work orders and administrative tasks. Ultimately, the goal is to ensure that complex products are built with the highest quality while keeping production lean and efficient.

Achieving Seamless Collaboration Between Engineering and Production

An integrated ERP system is essential for bridging the gap between engineering and production, providing the structure and control needed for complex builds while simplifying workflows for production teams.

In the end, it’s about creating a manufacturing environment where both engineering and production can thrive, working in harmony to deliver profitable products that meet both quality standards and market demand.

By Scott Ryan

For More Information

Scott Ryan, Sr. Consultant
Cetec ERP, LLC
Ph. 512-299-9170 ext. 116
E-mail: scott@cetecerp.com
Website: www.cetecerp.com
LinkedIn: https://www.linkedin.com/company/cetec-erp-llc/

The post BOM Strategies for Optimal Production Efficiency appeared first on IndMacDig | Industrial Machinery Digest.

However, for optimal success, automation companies rely on an accurate, complete single source of truth to facilitate a coordinated and efficient manufacturing process. Achieving this is easier said than done; there are multiple challenges along the way. A configuration technology approach can help address these challenges to increase engineering productivity, eliminate manual rework, and deliver a better customer experience.

Four Challenges Hindering Successful Automation

One of the main challenges for industrial automation is siloed systems. To optimize processes, increase efficiency, and realize digital transformation goals, alignment across functions is essential. However, many organizations today face difficulties due to silos, which make this alignment impossible. Ensuring that systems can communicate efficiently and doing so in an automated fashion is key. Manual efforts are not efficient and can introduce errors. Integrating the various systems so they can communicate is a crucial step.

A second challenge is the lack of data alignment, which stems from the problem of silos. Over the years, manufacturers have built up their data sets for engineering, sales, manufacturing, and service in different functions. Sometimes, language and descriptors cause a problem: Even a simple concept such as “voltage” can be modeled differently across departments (e.g., how is it expressed that there is an option where the equipment accepts both 240V and 400V?).

Descriptors and information tend to be structured differently from department to department, largely because each has a different perspective on the products. Engineers view a product differently than sales, for example. Sales is more focused on customer requirements and performance, which differs from the assembly and physical structure needed in engineering.

Similarly, the third challenge is a disconnect between manufacturing and engineering. Different tools and systems with different bills of material (BOMs) and functions are being used, making the idea of a universal BOM structure that could be used in all functions impractical. There isn’t one single structure that will meet all needs, so that approach is flawed.

Finally, industrial automation companies often struggle with significant technical debt, primarily caused by numerous legacy systems originating from home-grown solutions or acquisitions. These diverse technology ecosystems contribute to poor performance, constant rework, and frequent downtime.

A Better Approach to Aligning Data

The right approach to bringing these different functions together is to respect that certain structures work well in specific functions. Thus, a new structure should be created behind the existing ones to connect these functions effectively.

This is the thinking behind a configuration technology approach: you need another level of abstraction. It’s a structure where different views can coexist while still being linked. The terminology is features and feature strings. These feature strings act as the DNA that binds everything together. You can view your structure from an engineering perspective, with the associated DNA mapping to what’s happening in sales. Sales make choices on what configuration of the product is needed for a particular purpose, which maps to the DNA and to the structure in engineering. This is the key idea behind configuration technology and the “secret sauce” that ensures different views can coexist.

Efficient digitized processes are also important. When you have an update to your product, you can efficiently propagate it through the functions to ensure the updates are applied. If a mistake is discovered in a version of the product, you can fix it and quickly release the correction to all other functions to prevent recurring issues. Or, if you add a new feature to your product and want to get it to market quickly, digitized processes will enable that.

Bringing It All Together

Ultimately, you can create a shared source of product configuration that traverses engineering, manufacturing, and sales. By aligning data across departments and systems, industrial automation companies can reduce or eliminate configuration errors in the products they manufacture, get to market faster, and achieve greater customer satisfaction. Industrial automation companies that have adopted a configuration technology approach have eliminated manual rework, increased engineering productivity, and delivered better customer experiences.

By Henrik Reif Andersen, Chief Strategy Officer and Co-founder of Configit

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Rotary shaft seals are a perfect example. These crucial components seal the rotating parts of machinery, prevent lubricant leakage, and ensure impurities do not infiltrate the inner workings of engines, gearboxes, and pumps. Mechanical seals, specifically, are utilized for high pressure applications demanding robust sealing capabilities. Consequently, the seal assembly components must be ground to exceptionally precise levels of flatness and parallelism to operate as effective leak-proof seals.

Unfortunately, the grinding process can be lengthy, labor intensive, and costly with conventional methods. So, when production requirements increase, manufacturers frequently turn to more advanced, automated rotary surface grinders that can achieve the precise specifications in much less time, with less operator intervention and skill.

Exceptional Seal Fit and Performance

For rotary shaft seals, various factors affect seal selection, such as shaft speed, pressure, temperature, lubricant type, and environmental conditions.

Traditional designs typically involve three main elements: a metal case that provides rigidity and structural support; a rubber sealing lip that creates a tight seal around the rotating shaft; and a spring that ensures constant pressure is maintained by the sealing lip against the shaft.

However, these seals may not perform as expected at very high pressure or RPMs, where traditional seals can begin to struggle to maintain contact with the shaft (track) due to radial runout. In these cases, the spring is often unable to maintain a tight seal with the shaft.

“The seals may be rotating at 40,000 RPM and if there is an imbalance because a part was not ground to size or parallel, then it is going to throw off the whole system. The seal can become compromised, and eventually it will begin to leak,” says Jared Desrosiers, Manufacturing Process and Technology Manager, MAGSEAL, LLC, a supplier of specialty magnetic seals for critical systems that is celebrating its 70th anniversary this year.

In this type of scenario, magnetic seals create a strong attraction that eliminates the need for a spring in face seal designs.

“Magnetic seals are engineered to perform in high speed, high vibration, high altitude conditions and are excellent replacements for seals that are subjected to high torque, runout, and axial movement,” says Desrosiers.

The OEM’s magnetic seals, called MAGSEALs, provide 100% positive face to face sealing and are designed to operate in air, gases, water, steam, refrigerants, lubricants, fuels, and hydraulic fluids. The MAGSEALs are typically custom designed in a variety of sizes from a quarter inch to over 6 inches.

According to Desrosiers, MAGSEALs are comprised of a magnet (stator) and a seal case (rotor). When fully assembled, the attraction force of the magnet pulls the seal case assembly into itself to create a tight seal.

The magnet is made from Cast Alnico V, a combination of aluminum, nickel, cobalt, and iron, to create the seal. The seal case is made from a ferromagnetic material, 416 or 410 stainless steel, 17-4PH for maximum corrosion protection, or 42 Alloy steel for low thermal expansion. A carbon graphite ring is installed in the seal case to complete the assembly. The carbon ring purposely protrudes out of the seal case to a specified nose height which is meant to interface with the magnet.

Each of these components – the magnet, seal case, and graphite ring – requires precise grinding to specific dimensions, parallelism, and surface finish.

Although the seal case does not have to be as precise, the carbon rings that are pressed into it are ground, lapped, and polished to achieve the specified nose height. The carbon seal ring surface flatness should be within two helium light bands, 0.0000232 in. [0.000589 mm] prior to use, according to John Westgate, MAGSEAL Manufacturing Engineering Technician.

For the magnet, MAGSEAL starts with a rough casting and grinds all the sides and surfaces. Secondary lapping steps are required to achieve the necessary surface finish. Currently, the OEM estimates it grinds 1,500 to 2,000 magnets each week.

In the past, the OEM utilized conventional reciprocating grinders on the magnets. Although reciprocating table grinders can be precise, the material removal rate is slow since the workpiece travels back and forth under the grinding wheel, so many grind passes are required.

However, as production requirements increased, the OEM decided to replace a slow, aging reciprocating rotary surface grinder that often needed to be repaired with advanced rotary surface grinders from Winona, MN-based DCM Tech.

“We were able to achieve the precision and surface finish that we were looking for with the conventional method, but it took significantly longer to grind the same number of parts,” says Desrosiers. “With the [DCM] rotary surface grinder, we knew we could achieve significant time and efficiency gains.”

Today, rotary surface grinders are designed with much more advanced sensors and controls that automatically maintain very tight tolerances, removing material down to within one ten-thousandth of an inch of the final thickness. Digital technology allows for an interface with easy-to-use touchscreen controls.

To expedite the grinding and finishing process for the magnet line, the OEM recently upgraded from a conventional rotary surface grinder to a more automated, IG 282 SD grinder from DCM Tech with a 24” variable speed table and 20HP variable speed spindle.

“We have found that nothing achieves the necessary flatness, height, and parallelism as fast as the DCM Tech rotary surface grinders. The required parallelism is particularly important to prevent vibration at high speeds of rotation,” says Desrosiers.

The new model includes advanced features that automate the initial contact between the abrasive wheel and the part. With this updated option, advanced sensor technology detects vibration and can automatically fine-tune not only the pressure of the spindle motor but how quickly it moves the wheel down onto the part. When the machine senses the abrasive wheel has contacted the part, it automatically begins the grind cycle.

Automatic part detection eliminates the need for the operator to do time consuming, error-prone ‘manual touch offs,’ where they would manually feed the grinding machine until it just touches the surface of the part before backing off and restarting it.

“The DCM Tech grinder simplifies the skillset needed and makes training a new operator a lot easier,” says MAGSEAL Manufacturing Engineering Technician Westgate.

One of the reasons advanced rotary surface grinders are much faster than conventional reciprocating grinders is because the units can get much closer to the required dimensions before any finishing steps. In some cases, secondary steps can even be eliminated.

According to Desrosiers, the increased automation and ease of use has helped to dramatically improve magnet production.

“We increased manufacturing capacity with reduced setup, loading/unloading, and cycle time. We decreased the cycle time by more than 300%” says Desrosiers, adding that by reducing or eliminating the need for subsequent finishing processes, the company was able to achieve ROI in about three months.

MAGSEAL also appreciated the rotary surface grinder’s enhanced safety and cleanliness features.

Automated grinders contribute to a cleaner shop environment because the grinding is accomplished inside an enclosed shroud that contains the debris and prevents it from entering the work area. The shroud, which is a sliding door with a built-in window for viewing the process, encloses the grinding area. This has the added benefit of reducing the noise produced by the machine.

In addition to a shroud, grinders like the DCM IG series provide an integral air mist collection system that draws particulate matter from the air and moves it away from the operator to enhance the cleanliness and safety of the work environment.

“For us, safety is paramount. The advanced rotary surface grinder is a fully enclosed machine with door interlocks. This configuration is significantly safer and cleaner than a conventional service grinder,” says Desrosiers.

He notes that MAGSEAL has already ordered another advanced rotary surface grinder to replace an aging reciprocal grinder used for the initial “rough” grind of the magnets.

When manufacturers need high-performance components that reliably operate in the most rigorous conditions, precise grinding is often necessary to meet the exact dimensions, flat, parallel surfaces, and finishes. In these cases, utilizing advanced, automated grinders that precisely and efficiently hone the component parts will help ensure that the required quality, reliability, and production goals are met.

About the Author

Del Williams is a technical writer based in Torrance, California.

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Advanced Automation Systems

The expanded headquarters will enable Toyota to better serve its customers and continue its leadership in the industry. One of the key components of the expansion is the incorporation of advanced automation systems. These systems are designed to improve production efficiency, reduce operational costs, and enhance the quality of the company’s material handling equipment. By integrating cutting-edge technologies, such as robotics and IoT, Toyota aims to create a more agile and responsive manufacturing environment.

Sustainability Initiatives

In addition to technological advancements, the expansion project emphasizes sustainability. Toyota is investing in renewable energy sources, energy-efficient building designs, and sustainable manufacturing practices to reduce its environmental footprint. The new facilities will feature solar panels, energy-efficient lighting, and advanced HVAC systems to minimize energy consumption. These initiatives align with Toyota’s global commitment to sustainability and environmental stewardship.

Economic and Employment Impact

The expansion project is also expected to create hundreds of new jobs, contributing to the local economy and supporting the growth of the manufacturing sector. Toyota is committed to fostering a diverse and inclusive workforce, providing employees with opportunities for career development and advancement. The company’s investment in training and education programs will ensure that its workforce is equipped with the skills needed to thrive in a technologically advanced manufacturing environment.

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Integration of Renewable Energy Sources

One significant trend in sustainable manufacturing is the integration of renewable energy sources. Many manufacturers are investing in solar, wind, and other renewable energy systems to power their operations. This shift not only reduces reliance on fossil fuels but also helps companies mitigate the risks associated with fluctuating energy prices and regulatory changes. By generating their own clean energy, manufacturers can achieve greater energy independence and cost stability.

Circular Economy Principles

Another key trend is the implementation of circular economy principles. The circular economy aims to keep products, materials, and resources in use for as long as possible, minimizing waste and environmental impact. Manufacturers are embracing this concept by designing products for durability, repairability, and recyclability. They are also developing innovative processes to recycle and repurpose waste materials, turning them into valuable resources for new products. This approach not only conserves natural resources but also opens up new revenue streams and reduces waste management costs.

Advanced Manufacturing Technologies

Advanced manufacturing technologies, such as additive manufacturing (3D printing) and digital twins, are also playing a crucial role in promoting sustainability. Additive manufacturing allows for precise production with minimal material waste, enabling manufacturers to create complex parts and components more efficiently. Digital twins, virtual replicas of physical assets, help optimize manufacturing processes by simulating different scenarios and identifying opportunities for energy and resource savings. These technologies enhance product design, production efficiency, and overall sustainability.

Sustainable Supply Chain Practices

Sustainable supply chain practices are becoming increasingly important as manufacturers seek to reduce their environmental footprint. This includes sourcing materials from environmentally responsible suppliers, optimizing logistics to reduce transportation emissions, and implementing sustainable packaging solutions. Companies are also focusing on transparency and traceability in their supply chains, ensuring that their products are ethically and sustainably produced.

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Tebots, Inc., for example, is an industrial design-build firm with diverse experience designing devices, products, automation, and manufacturing to find solutions to seemingly impossible challenges through creative solutions. The company specializes in industrial prototyping and production. They have extensive and diverse experience that allows them to be bold and propose uncommon results, often in the form of an invention.

The founder of the company, Robert Tegel, considers himself a “disruptive innovator” and thrives on coming up with solutions to challenges that are thought to be unachievable. The solutions he creates are specifically designed to speed-up cycle times, reduce costs, and eliminate unnecessary complexity.

Tebots prides itself on offering tailored solutions rather than cookie-cutter approaches. With a focus on innovative methods and original ideas, they are the go-to company for those seeking transformative solutions. The only thing required of the customer is “a positive perspective to give me the go ahead to do something different,” says Tegel.

Tegel’s background

The strength of Tegel’s design-build experience lies in the diverse range of his specific background, resembling a “Swiss-army knife.” With a career marked by maintaining, engineering, and inventing various types of equipment, he views it as an “agglomeration of success.”

During his early years, he initially pursued a career as an auto mechanic but ultimately transitioned into diverse roles in the field. These included installing grain elevators, operating in foundries, improving high-speed sewing equipment, designing pumps for home coffee systems, manufacturing valve seals and inkjet cartridges, applying industrial testing and automation, and contributing to auto part assembly.

The common thread throughout his career is in the wide range of equipment he has handled.

“One piece of equipment was the length of a city block running very low RPMs and moving garbage and separating all kinds of different things and material processing different temperatures and heat and then going into stuff that was running 400 cycles per minute. And then the next job I took was microprocessor-controlled high speed sewing equipment that was running 10,000 cycles per minute,” says Tegel.

Throughout his career, Tegel left a string of inventions in his wake. His first patent was issued in 1988. Within the textiles industry, he devised an innovative patented solution for efficiently and repeatedly sewing t-shirt sleeves. His more than 30 issued patents include a pallet positioning system, a variety of dunnage systems and apparatus, and a discharge control valve.

Then, in 2005, he decided to go into business himself. The company began as Tegel Design. However, one customer was so thrilled with the engineering that he asked the company to manufacture the product. Industrial design-build firm, Tebots, was born in 2007 of this request.

The company’s name, Tebots, in many ways is a precursor of the now popular term “cobots”. A cobot, or collaborative robot, is a robot intended for direct human-robot interaction within a shared space, or where humans and robots are in proximity. An early Tebots logo depicted a robot engaging in a handshake with an individual, symbolizing the harmonious relationship between humans and machines – a philosophy infused in many of Tegel’s designs.

From those beginnings, they began to accumulate internal production resources such as machine centers, test and measurement equipment, and other production capabilities.

When parts are outsourced, the company works with supply chain vendors to receive high quality finished parts. Before delivering assembled sub-assemblies or complete machines, an exhaustive quality control procedure is carried out utilizing cutting-edge test and measurement systems.

Tegel now regards Tebots as a skunkworks-style operation – an innovative endeavor led by a select group of individuals operating outside the conventional research and development channels of the organization.

In every design, Tebots consistently aims to optimize material usage and streamline assembly processes while upholding high-quality standards. Meeting strict delivery schedules is an ongoing priority, with a dedicated focus on enhancing part efficiency, expediting production, and reducing costs. As such, Tebots’ designs are rooted in principles encompassing Design for Manufacturing (DFM) and Design for Assembly (DFA).

Design for Manufacturing (DFM) refers to the process of designing parts, components, or products with the objective of improving product quality while reducing costs through simplified, optimized, and refined product designs. Similarly, Design for Assembly (DFA) focuses on designing products that are easily assembled, aiming to minimize assembly time and associated costs by reducing the number of components involved.

To remain competitive against the Asian market, for example, Tegel has developed innovative strategies to streamline manufacturing processes and remove any unnecessary steps, ensuring efficiency and cost-effectiveness.

“There was constant competition with my customer to meet delivery costs in the Asian market, so I had to come up with extremely lean, net zero bill of materials,” says Tegel.

In one example, his customer was purchasing a machined structure to hold the machine up like a stand. They were buying them from China for $420, shipping them to the United States all welded together. Tebots produced the same part using patent pending tubular connections that provide a similar strength and rigidity to a welded connection for a third of the cost. The Omni Stand can be used to support just about anything that can be attached to it and disassembled easily if needed. The patented methodology, now called the OmniStand, is now being offered by Grundlage Solutions (https://grundlage.solutions/).

An Eye on Future Paradigm Shifts

According to Tegel, the primary objective in design-build is to devise a solution that is efficient, cost-effective, and feasible to meet the immediate requirement. However, he also consistently keeps an eye on future potential iterations or models.

“When designing, it is crucial to consider the potential development of the product over time, with an eye on how we can move to a new paradigm or segue into new way of doing things,” says Tegel.

So, when the pandemic occurred, Tegel identified an opportunity that he felt would hold significant value in the future beyond the crisis. Despite lacking dedicated customer funding for the project, he decided to invest his own efforts and expertise.

The result was a unique and patented UV disinfection system called the POZ. The device utilizes short-wavelength ultraviolet C (UV-C) light to inactivate pathogens including viruses (such as SARS-CoV-2), bacteria, mold spores, and yeast.

Never one to shy away from collaboration when required, Tegel reached out to Turan Erdogan, a former research professor at the University of Rochester’s Institute of Optics.

“Collaboration is key when it comes to areas where you may not have expertise,” says Tegel.

Although there are already many UV light devices on the market, Tegel and his team had to overcome several inherent limitations in design. Many require direct contact and manipulation to operate the appliance, and there can be questions about the intensity and contact time of the applied UV light. If the item is treated in a static manner, for example placed in an enclosure without being rotated or moved, it is like tanning on the beach on only one side. The UV-C light may not reach all the relevant surfaces.

“Simply adding a UV lamp to a product and expecting it to destroy pathogens does not mean it will be effective,” says Tegel. “UV light sources can vary in intensity and output, and there can be line-of-sight issues as well. You have to make sure the UV light is directed at the items from many angles with uniform intensity, and all this requires a high level of engineering.”

The patent-pending UV disinfection appliance resembles a small, portable charcoal grill. Tablet sized, or smaller items are placed on a rotating platform and then move in a 360-degree arc through the chamber where they are bombarded from all angles by UV-C light for approximately 10 seconds.

“Because the item is moving through the chamber, we can direct the UV-C in a way that ensures it will hit the targeted surface. By controlling the internal environment and the time within the chamber very precisely, we can kill more than 99.9% of the pathogens on the surfaces of the item,” says Tegel.

Tegel envisions the self-service disinfection stations being installed in front of entries/exits or bathrooms at public venues, retail stores, healthcare facilities, academic institutions, airport terminals, and nursing homes – to name a few. The units could be used to disinfect personal items such as cellphones, tablets, face masks, ID badges, baseball caps, sunglasses, keys, wallets, jewelry, credit cards, bills, and coins.

The company hopes to engage in discussions with several entities to license the technology. The initial design and several full prototypes have already been created.

Although at the time the primary driver to develop this technology was COVID-19, Tegel says the intention was to create a device that addresses both existing and future health challenges as well.

“This isn’t just a COVID-related product,” says Tegel. “It is a product and an approach that could have a lasting impact on hygiene now and in the future using a technology [UV-C] that has been around long before the pandemic.”

To remain competitive in their respective industries, many companies consider industrial design-build to be essential. Collaborating with an experienced and versatile industrial design-build firm can decrease cycle times, lower costs, and simplify operations by finding innovative solutions.

For those seeking creative and efficient problem-solving, partnering with a firm that can provide paradigm-shifting solutions can be an ideal choice.

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