Manufacturing Transformations: Building

Blocks Of A Future SMART Plant

Mon, 10/13/2014 - 9:54am
Rahul Vijayaraghavan
Imagine if an enterprise in the United
States was able to access vital product
line information of a subsidiary plant
in India or a crank shaft supplier being
able to locate its component in an
automobile across the globe or a
machine being to self-assemble at the
end
destination.
Technology
advancements over the last decade
have paved the way for all of the above
situations to be executed in repeatable
fashion. In this article we will explore
some of the key technologies
disrupting manufacturing operations as
we know them.
From Data to Intelligence
The advent of intelligent sensors and wireless technologies has paved the way for the
Internet of Things (IoT) to gain wide recognition across a number of end user verticals.
Although greater asset connectivity is poised to dissolve boundaries between individual units
in the industry, the increase in data traffic has resulted in a push towards software tools for
data management, visualization, and analytics. While integration and storage tools are
essential to aggregate, analyze, integrate, and store diverse structured and unstructured data
types, current business imperatives to optimize production operations in a cost effective
manner have resulted in an upsurge in demand for analytical platforms to measure key
performance indicators of mission critical operations. Apart from traditional analytical
platforms that where built with diagnostic capabilities, the market is witnessing an influx of
predictive and prescriptive analytics where predictive algorithms and pattern recognition
allow end users to take corrective measures prior to failure.
From a manufacturing standpoint, the greatest impact is expected for repair and
maintenance activities where personnel within the enterprise can take a proactive approach to
minimize costs incurred due to downtime of operations. The compelling benefits of closing
the data loop to provide real time business intelligence will further allow the enterprise to
optimize inventory management, improve resource productivity, and validate system
performance.
Cloud as an enabler

The power of cloud computing to connect a multitude of devices and platforms is yet
another transformation that is not only impacting manufacturing facilities, but also the
extended supply chain. In contrast to on-premise models, cloud based systems that have
greater processing power allow the enterprise to pay a nominal fee to store large volumes of
data. Furthermore, challenges such as accessibility are nullified as enterprises are no longer
required to find suitable locations for servers and IT personnel need not worry about software
updates. As traceability mandates become increasingly stringent across key vertical markets
such as food & beverage, pharmaceutical and automotive owing to product recalls,
contamination and counterfeits, a number of small and medium enterprises are leveraging
cloud based technologies to monitor products across the value chain.
An example to illustrate the use of cloud in the food & beverage industry is the
monitoring of time-critical perishable foods that have set temperature, pressure, and humidity
requirements. From farm to fork, value chain participants can track the custody transfer at
multiple points; be it at the manufacturing facility for batch verification, freshness, and
ingredient control or at the retail store where products can be stocked based on shelf life. The
ability of a diverse array of personnel to access information using smartphones not only
stimulates high growth for cloud based technologies, but also gives rise to a new era of
control-on-the go.
Chart 1.2: Drivers for MobilityControl-On-the-Go
As the perennial challenge of the aging workforce continues to plague the
manufacturing industry, the ability to pass down manufacturing and operational intelligence
to personnel at the shop floor is imperative. The penetration of smart phones and tablets in
conjunction with cloud based technologies has created an avenue for solution providers to
develop mobile solutions from their existing product portfolios. Furthermore, the ability for
end users to deploy a cost-effective commercial tablet rather than an expensive industrial
grade tablet not only reduces the cost of hardware and total cost of ownership but also
provides end users with the capability to invest in a larger number of tablets improving
response time, visibility, and accessibility of operations. From the shop floor all the wayto
the C-level suite of the enterprise, using role based dashboards and interactive user interfaces,
personnel can monitor and validate key performance indicators, such as line effectiveness,
capacity requirements, utilization rates, and process efficiencies. The recent evolution of
mobility through wearables reiterates the importance of enhanced visibility on the shop floor.
End users can now integrate wearables like Google Glass with enterprise legacy systems to
allow for real time data transfer between equipment operators, managers and almost any other
personnel across the enterprise.
Reshaping the future, 3D to 4D Printing
Manufacturing facilities are gradually witnessing an inflow of 3D printing techniques
to improve production efficiencies by minimizing lead time for the manufacture of new parts.
Although there is much debate on purchasing expensive state-of-the-art 3D printing
equipment versus outsourcing to a service provider, application specific requirements such as
volume, value, design database, material portfolio and engineering expertise are critical for
end users in deciding the most apt business model. For example; for high value/low volume
products in the medical industry, contracting a service provider would be a more viable
solution as the enterprise can design a number of cost effective prototypes, select the best
material fit and then decide whether to mass manufacture the product using traditional

manufacturing techniques or using 3D printing technologies. As research and development

(R&D) activities for new materials gain more traction, the market is witnessing a pronounced
transition shift from 3D printing to 4D printing. 4D printing, that facilitates the manufacture
of products that would have the potential to self-assemble or selfheal, is poised to disrupt a
number of end user segments. While specific end user segments are expected to witness
higher impact, such as in the automotive industry where vehicle coatings could respond to
varying environmental conditions, on the plant floor, packaging operations will have the
greatest impact owing to the numerous benefits of flexible packaging.
While the future of manufacturing looks bright, the biggest hurdles to the streamlined
transition of these new technologies are end user conservative mindsets and associated cyber
security risks. Currently, a number of solution providers are focusing efforts in the cyber
security space, where defense in depth strategies to add security clearances at each level (i.e.
control layer, network layer and application layer) are becoming an industry norm. Finally,
for end users that are not open to change, it is critical for solution providers to build a
business case that depicts a sizable return on investment in the shortest possible time.

http://www.manufacturing.net/articles/2014/10/manufacturing-transformationsbuilding-blocks-of-a-future-smart-plant

How Manufacturers Can Improve Product Design

Mon, 11/03/2014 - 4:46pm
Al Kent
Industrial companies are often perceived as lumbering giants that have difficulty
responding to competitive pressures and capitalizing on market trends. Design cycles can last
yearsnot just for developing new products but also for making upgrades to the existing
portfolio.
Why are many industrial manufacturers so sluggish? In my experience, these
companies have traditionally relied on a top-down, linear process that moves projects through
design gates, also called stage gates. The approach is often slow and bureaucratic, and its
mechanical nature can stifle creativity.
Fortunately, theres a better way. Industrial companies can take a page from the fastmoving world of software design and adopt a sprint-and-scrum approach. This iterative
process relies on short cycles involving rapid design evolution and revision. The sprint is a
period of concentrated effort, such as engineering or coding a module, by individuals or small
teams. At the end of each sprint, stakeholders from the key functions come together for the
scrum, where they review progress and clarify goals for the next sprint. The intense nature
helps bring the organization together toward a common goal, and avoids the tedium that can
set in with a long stage-gate process.
Sprint-and-scrum has been used to develop many of the most complicated designs in
human history. Take the Supermarine Spitfire, which was the main Royal Air Force fighter
aircraft during World War II. At the outset of the war, the British realized that to be successful
in the Atlantic theater, the aircraft would need significant improvements. Between 1936 and
1945, it changed engines, its loaded weight doubled, and its maximum speed increased by 90
miles per hour. The rapid evolution of the plane was possible only because of its iterative
design and testing approach.
People may argue that the speed of efforts like the Spitfire development was enabled
by enormous budgets and the sense of urgency imparted by war. And its a valid point: Over
the last 1,000 years, large-scale warfare has proven itself time and again to be the single
biggest catalyst for economic and technological innovation. But a closer look reveals that the
decision to iterate these projects quickly and decisivelyessentially, to sprint-and-scrum
was the biggest factor in their success.
Taking a sprint-and-scrum approach will bring most industrial manufacturers into
uncharted waters. But Ive seen firsthand how effectively the process can accelerate design
and lead to better results. It reveals risks early on, it minimizes project management
overhead, and most importantly, it energizes staff by showcasing achievements and fostering
open communication.
In a recent example, a large automotive component manufacturer was facing significant
pressure from foreign competitors importing less-expensive parts. In order to prepare for the

next round of contract bids and ensure future profitability, senior leaders decided to undertake
a series of rapid design-to-cost efforts on their major part categories.
They built a detailed cost model of each component to understand the main drivers of
the cost structure that then informed a series of sprint-and-scrum efforts focused on major
design changes. Further, the sprint-and-scrums identified several other structural and tactical
improvement opportunities, such as relocation of assembly to Mexico, better spans of control
within the manufacturing operations, and greater procurement effectiveness.
The company was able to implement a majority of the improvementsand it
achieved a cost reduction of about 9 percent across the key component groups. This allowed
the company to defend its existing contracts from competitors and, more importantly,
provided a truly unique approach to design that was leveraged across the organization.
As their competitive pressures mount, other industrial companies should take note.
Its time to remove the shackles that the stage-gate process can place on design. Whether they
are shooting for the moon or just looking for a way to quickly reset their products cost
positioning, the sprint-and-scrum approach will help companies get there.
Al Kent is a partner wiht Strategy&'s operations practice, and is based in Florham Park, N.J.

http://www.manufacturing.net/articles/2014/11/how-manufacturers-can-improveproduct-design

Manufacturers Gear Up For More Energy

Efficiency
Fri, 10/17/2014 - 12:00pm
Wayne Kovach
The Better Plants Program recently recognized eleven manufacturers for their efforts
in reducing energy consumption. The energy-efficiency based government initiative enrolls
businesses that commit to reducing their energy intensity by 25 percent over a ten-year span.
The intensity refers to the measure of a facilitys energy use per unit of output. The
Department of Energy (DOE) announced an impressive 2.4 percent combined improvement
over the last four years by the programs participants.
Requirements for enrollment include development of an energy use baseline for
tracking purposes, designation of an energy manager, the 25 percent commitment, and a
yearly progress report. Any company in the U.S. manufacturing industry can participate
regardless of size. Benefits include a feature on the DOE website, access to a technical
account manager for support in establishing energy use data and tracking, in-plant energy
management training, and a letter and DOE plaque upon achieving a ten year target.
The department reported that more than 140 companies currently participate in the
Better Plants Program, representing more than 2,300 manufacturing facilities and close to 11
percent of the total U.S. manufacturing energy footprint. Additionally, the program recently
welcomed 23 new members ranging from aluminum companies, to printers, to food
manufacturers. The Better Plants Program is included in President Obamas Better Buildings
Challenge, which enrolls universities, schools, multifamily housing, and local and state
governments that commit to reducing their energy use by 20 percent or more.
The table below shows the number of participating companies and the reported
savings from the Better Plants Program.
Image courtesy of the DOE.

At a time when the

manufacturing
industry
struggles
with
overregulation, businesses
that step up and take a lead
role in energy reduction
pave the way for future
success. These companies
are helping to save money,
create jobs, and promote
energy security. Energy
Secretary Ernest Moniz
stated:
Through
costeffective energy efficiency
improvements in their
factories, American manufacturers are boosting their energy productivity, saving money and
protecting the environment by reducing carbon emissions. As a result, Better Plants Partners
have avoided 18.5 million metric tons of carbon emissions to date, which is about the same as
the annual emissions from close to five coal-fired power plants.
Taking advantage of government programs that aid in cost reduction and
competitiveness within the industry is critical for the success of each individual business and
for the U.S. economy.
Wayne Kovach has worked as the SEO Specialist for Energy Curtailment Specialists since
2012.

http://www.manufacturing.net/articles/2014/10/manufacturers-gear-up-for-moreenergy-efficiency

Manufacturing Technology Trends Shaping The Industry

Mon, 11/03/2014 - 9:53am
Christina Chatfield
Manufacturing has changed drastically in the past
decade, and much of this change is due to advancements
in technology. Here is a look at a few of the technologies
that are having the largest impact.
Government-funded manufacturing hubs
One of the most impressive changes in
manufacturing is the renewed awareness of government
officials and economists that manufacturing is the real
engine behind a robust economy. President Obama has commissioned and funded various
manufacturing hubs around the country to focus on advancing the state of the art in
manufacturing and many new and promising manufacturing techniques.
The manufacturing hubs are consortiums of private businesses, public officials and
university-led researchers all focused on a particular promising manufacturing technology. To
date, several manufacturing hubs have been opened, including:

The National Additive Manufacturing Innovation Institute in Youngstown, Ohio

The Next Generation Power Electronics Manufacturing Innovation Institute at North

Carolina State University

The Lightweight and Modern Metals Innovation Institute in Detroit, Michigan

The Digital Manufacturing and Design Innovation Institute in Chicago, Illinois

The National Network for Manufacturing Innovation which oversees general

manufacturing research

These institutes are spread across the country and serve as centers of excellence for
manufacturing innovation. In addition, these institutes are helping to increase the respect for
manufacturing as an industry and a profession while advancing the underlying technologies.
Additive manufacturing mania
Additive manufacturing, also known as 3-D printing, has been gaining a majority of
the publicity devoted to manufacturing over the past year. From appearances on popular
television shows to packed booths at trade shows, 3-D manufacturing has captured the
imagination of manufacturing professionals and the general public.
Far from being a novelty, 3-D printing is proving itself to be a true game changer. No
longer relegated to printing ungainly plastic components, 3-D printing has rapidly evolved to

the point where it can produce items made of metals, mixed materials and even human tissue.
The result is shorter lead times, improved quality because of fewer components, reduced
waste and the ability to produce complex shapes without complicated machining. Additive
manufacturing is causing changes in the way engineers and designers think about creating
products and components, and it is changing the way we will educate and train future
generations.
Cold spray improves longevity of parts and equipment
While 3-D printing gets most of the press, another additive manufacturing process
known as cold spray, or 3-D painting, is shaking up traditional manufacturing as well. Cold
spray involves pushing metal powder through a nozzle under pressure. Cold spray can be
used to create parts from scratch or to apply coatings to traditionally formed items, but one of
the most interesting uses is to repair or refurbish used components by filling in worn spots
using materials that meet or exceed the original material specs. This repair process can extend
the life of machinery and equipment, tooling, dies and components by years. Restoring worn
items using cold spray results in greater return on investment, less downtime, faster return to
production for down equipment, and overall longer mean time between failure or necessary
replacement.
Nanotechnology
While nanotechnology doesnt have its own government-sponsored innovation
institute yet, it does have a government-funded initiative and it is one of the most interesting
technologies to come along in years. These tiny machines have been enlisted for such diverse
purposes as delivering cancer-fighting medications directly to the site of a tumor, repelling
stains on clothing, and extending the life and efficacy of lubricants. Long the subject of
science fiction, nanotechnology is coming into its own and reaching the stage where results
are repeatable and commercially viable.
IoT
IoT, otherwise known as the Internet of Things, is the growing ability for devices to
communicate automatically with one another over the Internet without requiring input from
people. This new communication ability has been the subject of late-night gags about the
refrigerator calling its own repairman, but in reality IoT is having a profound effect on
manufacturing.
Equipment now monitors its own status and not only notifies repair and maintenance
teams when regular updates or PMs are due, it also continually checks its own performance
and calls for repairs or recalibration when it notices reductions in its efficiency or throughput.
Sustainable manufacturing initiatives
Many manufacturers are trying to reduce their carbon footprint as well as energy use
and overall environmental impact. These forward-thinking manufacturers work continuously
to educate the industry on sustainability, innovative technology and best practices that
produce high-quality, cost-effective products with less damage to the earths delicate
ecosystem.

While these are not the only manufacturing technology trends that are changing the
face of manufacturing, they are some of the more interesting and impactful trends. Taken as a
whole, they show that the manufacturing industry is one of the most innovative areas as well
as a strong driver for the economy. Watching these trends evolve and other innovations
emerge will prove interesting over the next several years.
Christina Chatfield is the Marketing Communications Manager for HARTING USA
(www.harting-usa.com) in Elgin, IL. HARTING Technology Group develops, manufactures
and sells products such as electronic and electrical connectors and cables for your
specialized manufacturing needs.

http://www.manufacturing.net/articles/2014/11/manufacturing-technologytrends-shaping-the-industry