Physical Testing is Alive and Well Throughout the Engineering World

In this digital world, it may be hard for some to believe that there’s still a place for anything manual or physical – especially in the engineering realm. And, while it’s true that today’s technologies have cut into the dependence on physical testing, real-world data remains the lifeblood of the product lifecycle.

From product design to troubleshooting in-service equipment, next generation product planning, and all phases in between, testing remains critical to the design, manufacture, quality, performance, and evolution of virtually all products.

New Product Development

For centuries the process to create or enhance a product consisted of building and testing a long series of prototypes. This build it/test it/break it approach was generally repeated until a satisfactory design was identified. While effective, the process was both costly and time consuming — with these factors often limiting innovation.

Since the late 1960s technologies such as Computer-Aided Design (CAD), Computer-Aided Engineering (CAE), and simulation, have continually evolved to lessen the dependence on physical prototype testing and thus shorten development cycles. These tools allow 3D representative digital models to be created and analyzed for manufacturability, performance, durability, and reliability at component, sub-assembly, assembly, and product levels.

Read the article here in Power & Motion Magazine.

The 8 Most Common Efficiency GAPS in Plastics Operations

Plastics processors are living in a digital world; and technology is profoundly changing the way everyone lives, interacts, communicates, works and does business. While all industries have benefitted, perhaps none are impacted quite like manufacturing. Findings here show that integrating processes, advancing efficiency and accelerating workflow generate as much as 25% to 40% return on technology investment. And that’s just the tip of the iceberg. As technology continues its rapid development, optimizing internal processes will impact efficiency, quality, throughput and profitability exponentially.

Optimization is all about getting the most reliable, accurate and timely information needed to provide the insight to achieve the desired results faster and in the least expensive and most efficient way. These days that means the integration of robust business and manufacturing applications. Conversely paying little or no attention to the widening gap between processes and optimization technologies can quietly erode the fair market value of a manufacturing company. Although the advantages are well documented, a surprising number of manufacturers, especially those in the plastics industry, are slow to embrace these new technologies.

It’s time for an analysis.

Most plastics processors probably assume that they are on solid ground. After all, the machines are running, the bills are being paid and the lights are burning. But could they be doing even better? Do they really know where their company ranks in terms of operational optimization?

This Plastics Processor Gap Analysis will help processors learn how their company stacks up against the eight most common efficiency gaps.

Read the Plastics Business Magazine article here.

Subjective Quality Testing is Becoming a Thing of the Past

What comes to mind when you look at your automobile, washing machine, lawn mower, or any other product? For many, it’s the manufacturer’s name attached to that product. And to protect their brand, reputation, and market share, those manufacturers are increasingly diligent about quality. And for an OEM, that includes all Tier 1 and Tier 2 suppliers.

Christopher Kus, Project Engineer and NVH Expert for the Automotive Seating Business Group-NAO of Faurecia explains that consumers rarely differentiate between the system and its components.

“Sub-system and component flaws generally create overall negative feelings toward the system as a whole,” said Kus. “For example, a rattling window, unreliable ventilation fan, or noisy seat motor will result in a reputation for poor quality for the entire vehicle. Consequently, OEMs are increasingly vigilant with supplier quality.”

Faurecia Seating seat systems optimize the comfort and safety of occupants while offering premium quality to its customers. By objectively quantifying quality, Faurecia is meeting and exceeding customer (and end-user) expectations.

Read more here.

Cracking the NDT Code

I recently sat down with Mark Koehler, Professional NDE (PNDE) Services Group’s business development manager, and Neil Coleman, Signalysis Inc.’s founder and president, discussed non-destructive testing (NDT) methods and how it applies to weld inspection.

During the conversation, Neil and Mark offered a host of information regarding the various types of NDT as well as the information about the products and services their companies provide in that regard.  Neil also explained how some of the roots behind NDT can be traced to the rocket era.

Read it here.

Fabrication: Beyond Flat Plate

In any business, adding capabilities and services can have a measurable impact on the bottom line. And many fabricators have expanded their offerings to attract customers from new industry sectors. This could include adding painting, welding, laser cutting, beveling or bending to a company’s operations.

Living in a 3-D world, more fabricators are beginning to venture beyond flat plate cutting to diversify their offerings. But processing pressure vessels, boilers and similar 3-D objects generally presents some unique and significant challenges. As with any traditional job, cutting operations must be fast, simple to set up, and produce clean and accurate results that won’t require added manual cleanup. When it comes to 3-D objects, however, this is often easier said than done.

The dome cutting process typically includes creating openings in the dish end of the vessel to allow for the welding of inlet pipes or slicing or trimming of the edges and to prepare the end to be welded to the vessel body. Accuracy is critical as the cross-sections of the cut edges must meet the requirements of the subsequent welding process. Depending on the wall thickness, V, X or K cuts with constant or variable bevels must meet the prescribed accuracy. Failure to do so means poor quality, excessive scrap and lost contracts.

Read more here.

MANUFACTURING MONTH IN REVIEW

Companies choose to mark the occasion in any number of ways. While some are content to simply wave the banner, others like Cincinnati Incorporated are making a real difference in the lives of students and the future of the industry. Each year in October, Cincinnati Incorporated (CI) hosts students from the area’s local high schools, vocational schools, and technical colleges. These days include facility tours, a chance to interact with the company’s engineers and professionals, and an opportunity to see some of the industry’s leading machine tools in action.

Read about it here.

Drilling and Milling Solutions Turn Cutting Machines into Multi-Functional Production Centers

Fabricators throughout North America have wider access to some of the industry’s most sought-after cutting equipment. Fabrication processes often require high-precision holes, threads, or countersinks. Whether its flanges, end plates, heat exchanger tube sheets or generally any stress-exposed bolted joints, there are many applications where it is technologically necessary to create the holes by drilling. While there are jobs – especially those with large quantities of holes in a single workpiece or assembly – where using a dedicated boring machine is most efficient, there are also many parts that require just a few holes and perhaps some threads.

Ideally, these parts would be manufactured with a single machining center including cut contours, markings, and machined holes. But, lacking this option, this work is usually done manually, or via a separate mechanized drilling process adding time and cost to the job.

Read more here.

How Simulation-based Training Enhances Visual Literacy

Visual Literacy is a subset of Sensory Literacy, a broad term that describes how critical thinking, is fueled by information acquired through the senses. This visual literacy is defined as the ability to interpret, negotiate, and draw conclusions from information presented in the form of images.

There is no shortage of examples. Charts, maps, and graphs convey geographical information, demographics, sales data, and similar information much more clearly than words. A photograph or video validates an event better than dialogue, hearsay, or an online post.

Read this article to learn how simulation-based training is bridging the learning gap for new equipment operators.

Built to Tilt

Representing some of the world’s most reputable CNC machine tool builders, United Precision Services provides equipment to North American manufacturers focused on producing medium to large
parts using machining and fabrication processes. A recently announced partnership between the company and MicroStep, a CNC cutting machinery manufacturer, injects new technology into the market in the form of bevel cutting mild steel and stainless steel on a traditional gantry-style machine using a rotator head using fiber laser technology.

I caught up with United Precision’s national sales manager, John Prevish, to learn a bit more about this bevel cutting technology and what benefits this partnership brings to the North American metal fabrication market.

Read the interview here.

From the supply chain disruption to mounting material and overhead costs, and tightening delivery schedules, manufacturers across the board are challenged on multiple fronts. As baby-boomers age out of the workforce in record numbers, you can add a labor shortage to the list. And, as if they needed more to worry about, consumer demand is on the rise forcing manufacturers to do more with less.

Cincinnati, Inc. (CI) is answering the call with a new wave of press brake technology designed to automate and streamline metal fabrication. Recent innovations include the Sheet Following System, Dynamic Thickness Compensation, and an automated press operation solution known as ROBOFORM.

Read the article here.