by Gary Mintchell | Jan 30, 2020 | Manufacturing IT, Podcast
I have released a new podcast.
In the late 1970s I worked in an engineering department where one of my responsibilities was the custodian and distributor of all engineering data. In addition, I did all the corporate new product quoting–such things as UPS truck bodies and the bodies for the original Atlanta Airport People Movers. Everything was paper and manual. Drawings to bills of material to routings to costing.
Today we do the same tasks, except that everything is digital. The drawings are all digital files, the BOM–digital, sorting/costing/checking all faster and digital. We adapt and adopt technology to do things better.
The problem remains–leadership and management of the systems to implement all these technologies in order to reap the rewards.
That–is the challenge before us.
http://traffic.libsyn.com/automation/202_Industrial_Challenge_for_2020.mp3
by Gary Mintchell | Jan 29, 2020 | Education, Personal Development
For your personal development, I just finished and highly recommend a rather big (530 pages), but readable, book on thinking–Surfaces and Essences: Analogy As The Fuel and Fire of Thinking. The authors are Douglas Hofstadter and Emmanuel Sander. You may remember Hofstadter from an earlier book, Gödel, Escher, Bach: An Eternal Golden Braid.
Don’t let the size scare you off. It is quite an enjoyable read packed with everyday examples and ending with the fascinating examples of mathematicians pursuit of solving quadratic equations and the development of Einstein’s thinking as he came up with his many theories that explained gravitation and mass-energy unity.
Analogy is the selective exploitation of past experiences to shed light on new and unfamiliar things belonging to another domain. Analogy-making is the lifeblood of cognition. It is also is the wellspring of creativity. As they explore analogy making, they touch on the education establishment’s tendency to believe in teaching things–especially science and math–with formal logic rather than analogy. This latter is ironic because so many advances in math are accomplished through analogy and not through formal logic.
This book’s summary of research and story of stories added to my knowledge and experience about how importance of story over lists of facts. Even in science and technology. Partly because sometimes what we take as facts really aren’t. I am betting that you all have developed new technologies or applications because you’ve visualized them first and then proceeded to search for the appropriate solution.
Go dive into the story. It’s fascinating…and life-changing.
by Gary Mintchell | Jan 28, 2020 | News, Personal Development
I interrupt the regularly scheduled programming for this public service announcement.
There was a section of a political science class I took somewhere around 1968 where we discussed media and politics. (Yes, Virginia, that was a topic oh so long ago.)
We did some research and discovered, hold on you won’t believe this, that people tended to read what reinforced their political views. People of liberal persuasion tended toward The New Republic (liberal in those days) and people of conservative persuasion read something else (I forget this morning the title, probably something with Bill Buckley).
This morning I was scanning a couple of my carefully selected news sources that used to just provide me with short, to-the-point news items. Unfortunately, they are slipping into the mainstream “journalism” news + analysis stuff.
Today’s lead on one site was–hold on, you won’t believe it–people tend to watch TV news that supports their political philosophy. Conservatives watch Fox, liberals something else. They even looked at favorite TV shows.
I could almost feel the breathless exclamations of surprise through the prose.
I believe that it is Heraclitus I could paraphrase as saying there’s nothing new under the sun.
Since I haven’t watched TV news outside of what I’m forced into in airport gate areas for 30 years, and I don’t watch any of the TV show genres they mentioned (occasional episodes of “Diners, Drive-ins, and Dives” along with a diet of European soccer didn’t make their list), I guess I remain firmly in the “no political party would have me” camp.
So, go read what you read and don’t let anyone make you feel bad about your choices. You will feel better, and then you can go out and develop and apply technology to make our industrial and manufacturing systems operate ever better.
by Gary Mintchell | Jan 27, 2020 | Automation, Technology
As you add electronic sensing and control and networking to machinery, you can take a process to the next level. I’ve been impressed with the growing development of tighter tolerances and then better variety of materials for 3D printing (additive manufacturing). Here is an example of expanding the use of automated “subtractive” manufacturing—micro machining.
6-D Laser LLC was formed in 2018 as an affiliate of leading nanometer-level motion control specialist ALIO Industries, with the mission of integrating ultrafast laser processing with precision multi-axis motion systems. 6-D Laser offers Hybrid Hexapod-based laser micromachining systems for wide-range taper angle control, 5-Axis Laser Gimbal-based systems for laser processing 3D substrates, and unlimited field of view scanning solutions for laser processing large-format substrates.
Coming out of stealth mode and coinciding with its official launch in 2020, 6-D Laser has launched its website (www.6dlaser.com), and has also announced that the company will be showcasing its radical new approach to laser micro processing at the SPIE Photonics West event, booth 2149, 4-6 February in San Francisco, CA.
6D Laser’s central mission addresses limitations of existing laser processing systems which are largely due to sub-optimal positioning systems used by most system integrators. 6-D Laser tackles this problem by integrating ultra-fast laser material processing with the 6-D nanometer-level precision motion control solutions in which ALIO Industries specializes.
At the heart of 6-D Laser’s integrated ultrafast laser micromachining system is ALIO Industries’ Hybrid Hexapod, which takes a different approach to traditional 6 Degree of Freedom (6-DOF) positioning devices, and exhibits much higher performance at extremely competitive prices. Rather than 6 independent legs (and 12 connection joints) ALIO’s approach combines a precision XY monolithic stage, tripod, and continuous rotation theta-Z axis to provide superior overall performance.
The combination of serial and parallel kinematics at the heart of ALIO’s 6-D Nano Precision® is characterized by orders-of-magnitude improvements (when compared to traditional hexapods) in precision, path performance, speed, and stiffness. The Hybrid Hexapod® also has a larger work envelope than traditional hexapods with virtually unlimited XY travel and fully programmable tool center point locations. The Hybrid Hexapod® has less than 100 nm Point Precision® repeatability, in 3-dimensional space.
6D Laser vertically integrates all of the sub-systems required for precision laser micro-processing, and it does this by forming strategic partnerships with key component and subsystem suppliers that are required to achieve the goals of demanding precision applications. In addition to its association with ALIO, 6-D Laser has also partnered with SCANLAB GmbH, which together with ACS Motion Control, has developed an unlimited field-of-view (UFOV) scanning solution for coordinate motion control of the galvo scanner and positioning stages called XLSCAN. 6-D Laser has also partnered with NextScanTechnology to provide high-throughput scanning systems that take advantage of the high rep-rates in currently available in ultrafast lasers, and Amplitude Laser, a key supplier of ultrafast laser systems for industrial applications.
Dr. Stephen R. Uhlhorn, CTO at 6-D Laser says, “Introducing an integrated ultrafast laser micromachining system that combines the positioning capabilities of the Hybrid Hexapod®, with high-speed optical scanning leads to a system that can process hard, transparent materials with wide-range taper angle control for the creation of high aspect ratio features in thick substrates, without limitations on the feature or field size.”
Ultrafast laser ablative processes, which remove material in a layer-by-layer process, result in machined features that have a significant side wall taper. For example, a desired cylindrical hole will have a conical profile. Taper formation is difficult to avoid in laser micromachining processes that are creating deep features (> 100 microns). Precision scanheads can create features with near-zero angle side walls, but they are limited to small angles of incidence (AOI) and small field sizes by the optics in the beamline.
Uhlhorn continues, “6-D Laser’s micromachining system controls the AOI and resulting wall taper angle through the Hybrid Hexapod® motion system, and the programmable tool center point allows for the control of the AOI over the entire galvo scan field, enabling the processing of large features.”
About 6-D Laser LLC
6D Laser, LLC, an affiliate of ALIO Industries, Inc, was founded in 2018 by C. William Hennessey and Dr. Stephen R. Uhlhorn. ALIO Industries is an industry-leading motion system supplier, specializing in nano-precision multi-axis solutions. 6D Laser was formed with the mission of integrating ultrafast laser processing with precision multi-axis motion systems, including ALIO’s Patented Hybrid Hexapod. The integration of ALIO True Nano motion systems with key sub-system suppliers, through strategic partnerships with Amplitude Laser, SCANLAB, and ACS Motion Control, enables a new level of precision and capability for advanced manufacturing.
www.6DLaser.com
www.microprm.com
by Gary Mintchell | Jan 24, 2020 | Data Management, Manufacturing IT
Digitization is on everyone’s lips these days. If you have not taken steps to implement and improve digital data flow, you are probably already behind. I receive information regularly from PwC and here is a new report on how digitization is reshaping the manufacturing industry. The report takes a look at 8 companies and showcase how they improved their efficiency, productivity and customer experience by ensuring they have the right capabilities central to their operating model and by matching them with strong skill sets in analytics and IT.
Pressure from the consumer, new regulations and advances in information technology are all reasons that are pushing manufacturing organizations to digitize so they can avoid falling behind the new breed of market-leading ‘digital champions.’ The report identifies 4 significant changes CEOs must implement to maximize the benefits of digitization.
1. Drive organizational changes that address new digital capabilities and digitalized processes – e.g., product and process design and engineering, end-to-end procurement, supply chain/distribution and after-sales – right from the top, because these are so new and different
2. Hire more software and Internet of Things (IoT) engineers and data scientists, while training the wider workforce in digital skills
3. Learn from software businesses, which have the ability to develop use cases rapidly and turn them into software products
4. Extend digitalization beyond IT to include significant operational technologies (OT) such as track and trace solutions and digital twinning
From the report, “Already, digitally ‘smart’ manufacturers are gaining a competitive advantage by exploiting emerging technologies and trends such as digital twinning, predictive maintenance, track and trace, and modular design. These companies have dramatically improved their efficiency, productivity, and customer experience by ensuring these capabilities are central to their operating models and by matching them with strong skill sets in analytics and IT. “
During 2018 and early 2019, PwC conducted in-depth digitisation case studies of eight industrial and manufacturing organisations in Germany, the US, India, Japan and the Middle East. Drawing on discussions and interviews with CEOs and division heads, we explored the key triggers for change these companies faced, assessed how digital solutions are being implemented and how digitisation is affecting key aspects of their operating models. We also compared our eight organisations with other publicly cited digitisation case studies, and leveraged PwC’s 2018 study Digital Champions: How industry leaders build integrated operations ecosystems to deliver end-to-end customer solutions and other ongoing PwC research.
This paper is the result of ongoing collaboration between PwC and the Global Manufacturing and Industrialisation Summit (GMIS). GMIS provides a forum for industry leaders to interact with governments, technologists and academia in order to navigate the challenges and opportunities brought about by the digital technologies of the Fourth Industrial Revolution. PwC has been a knowledge partner with GMIS since 2016.
The eight case studies in this report make clear how far the role of digital technology goes beyond traditional IT systems. It also encompasses OT and data and analytics technologies. Full integration and linkage among these different technologies, and the ecosystems they are part of, are essential to a successful digital transformation. Yet success is impossible without a digitally smart workforce that is familiar with Industry 4.0 skills and tools.
These challenges are the subject of the second part of the report Digital Champions: How industry leaders build integrated operations ecosystems to deliver end-to-end customer solutions, which will be published in January 2020.
The report will elaborate further on the emerging theory of digital manufacturing and operations, in which successful, digitised industrial organisations will increasingly have to act like software companies in response to four key factors:
- The connected customer seeks a batch size of one, necessitating greater customisation of products and delivery time, improved customer experience, use of online channels and outcome-based business models.
- Digital operations require both engineering and software abilities to enable extensive data analysis and IoT-based integration, as well as digitisation of products and services.
- Organisations need augmented automation, in which machines become part of the organisation via closely connected machine–worker tasks and integrated IT and OT.
- Future employees will be ‘system-savvy craftspeople’ with the skills to use sensors in order to collect and analyse accurate data, as well as design and manage connected processes.
About the authors
Anil Khurana is PwC’s global industrial, manufacturing and automotive industry leader. He is a principal with PwC US.
Reinhard Geissbauer is a partner with PwC Germany based in Munich. He is the global lead for PwC’s Digital Operations Impact Center.
Steve Pillsbury is a principal with PwC US and the US lead for PwC’s Digital Operations Impact Center.
