Assembly - 07 Jul 2009

ASSEMBLY

July 2009

www.assemblymag.com

Technology Makes an Impact pg 20

State of the Profession

24

Bonding a Trailer

38

™

™

Optimum – The Clear Advantage

EFD’s new syringe barrels, cartridges and pistons set a new standard in consumable fluid dispensing and packaging components.

800-556-3484 +1-401-431-7000 www.efd-inc.com/ads/asm-0709

July 2009

Vol. 52, No. 7

20

ASSEMBLY 66

COVER STORY

24

20 Technology Makes an Impact 䡵

New technology gives impact wrenches the ability to measure torque and angle.—John Sprovieri

FEATURES

38

䡵 24 Ready for the Recovery

DEPARTMENTS

Our annual State of the Profession survey indicates that assemblers are worried, but cautiously optimistic. —Austin Weber

䡵 38 Adhesives for Trailer Assembly 40

Structural adhesives help assemblers of trucks, trailers, buses and other specialty vehicles reduce costs, boost throughput and improve aesthetics.—Brian Noonan

Assembly Lines . . . . . . . . . . . . . . . . . . . . . 15 Cleveland plant to build “green” engines.

Assembly in Action . . . . . . . . . . . . . . . . . . 18 Coiled spring pins improve steering assembly.

Moving Forward . . . . . . . . . . . . . . . . . . . . . 19 Sun rises on new plant for making solar panels. —John Sprovieri

Product Reviews . . . . . . . . . . . . . . . . . . . . 42 In-depth profiles of the latest assembly technology.

Classified . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Case Studies in Assembly . . . . . . . . . . . . 48 Learn how our advertisers have helped assemblers solve problems.

DEPARTMENTS Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Whose back yard?—Don Hegland

Automation Profiles . . . . . . . . . . . . . . . . . . 8

Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Advertisers Index . . . . . . . . . . . . . . . . . . . . 63 Leading Lean . . . . . . . . . . . . . . . . . . . . . . . 64

Systems integrator builds mousetraps better.—John Sprovieri

New & Noteworthy . . . . . . . . . . . . . . . . . . 12 Ultrasonic gripper picks up wafers without touching them.

We Fed It . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 One bowl is better than two.—John Sprovieri

NEXT MONTH

Cover photo courtesy Atlas Copco Tools & Assembly Systems 2 ASSEMBLY / July 2009 www.assemblymag.com

Selective Soldering Automating Battery Assembly Equipment for Spraying Dots What’s New in Linear Actuators

IF THIS IS HOW YOU THINK OF TURCK,

WE’D LIKE TO MAKE SOME IMPORTANT POINTS.

Remote I/O Products

MORE THAN JUST SENSORS AND CABLES... TURCK REMOTE I/O.

I/O Stations

Modular I/O Systems

OUTSIDE the Enclosure

BL67

r
$POOFDUPSJ[FE r
'SFF
DPOàHVSBUJPO
TPGUXBSF r
*OUFHSBUFE
WBMWF
JOUFSGBDF

INSIDE the Enclosure

BL20

r

*OUFHSBUFE
NPUPS
TUBSUFST r
'SFF
DPOàHVSBUJPO
TPGUXBSF r
"$
*0

piconet ®

r
.JOJBUVSF
TJ[F r
$POOFDUPSJ[FE r
)JHITQFFE
àCFSPQUJD
TVCOFU

AIM

r
ž
UP
ž$ r
3VHHFE
(
TIPDLWJCSBUJPO r
'VMMZ
FODBQTVMBUFE

FD20

r

)JHIFTU
EFOTJUZ
smallest footprint r
%SJWF
JOUFSGBDF r
0&.
BQQMJDBUJPOT

The best I/O available. No matter what I/O you need, we’ve got you covered. TURCK has a complete line of I/O products designed to save you time and money. With five product families and thousands of part numbers, TURCK has exactly the right product for your applications. Many I/O products are custom designed for specific applications, including interfacing directly with motors, drives, valves, operator panels, push buttons and analog and digital sensors. With TURCK you don’t have to be locked into proprietary PLC I/O solutions. From your PLC to every point in your automation application, TURCK works! Visit our website today to order a Network I/O catalog containing over 590 pages of innovative products.

Call us with your next application:

1-800-544-7769

email: [email protected]

www.turck.com

©2009 TURCK, Inc.

ASSEMBLY ONLINE ASSEMBLY in print is only part of what we have to offer. For the complete assembly picture of product assembly in manufacturing, log on free of charge to www.assemblymag.com.

Visit www.assemblymag.com

Click on

Web Extras

for the latest product information, video presentations on ASSEMBLYtv and the interactive AssemblyBlog blog page.

Get the bench you need and get it fast.

State of the Profession Report Click on our online “Web Extras” section for more information on the 2009 State of the Profession report.

Job Search

Your work can’t wait. With Pro-Line’s “In Stock” Program it doesn’t have to. You can get the exact modular workbench your application demands in 5 days or less, with your choice of work surface, color, and many accessories and options.

Online Jobs Page Check out ASSEMBLY magazine’s online jobs page. Specifically tailored for those with careers in manufacturing and engineering, it is quick, easy and free. Companies that are hiring can also go online in search of talent.

• For decades, Pro-Line workbenches have been synonymous with quality, functionality and unmatched ergonomic design. • Choose from the Millennium II electric height adjusting workbench, our most popular Model HD, the manual height adjust Ergo-Line, the Dimension Next Modular Workstations, and more. • Configure your workstation with accessories that include power supplies, bin holders, overhead lighting, adjustable shelves, and modular drawers.

Click on

Industry Headlines

Updated daily, ASSEMBLY’s online “Industry Headlines” section allows you to catch up on the latest in assembly investment and innovation, both in the United States and abroad.

Click on

Showrooms

1proline.com (800) 739-9067 4 ASSEMBLY / July 2009 www.assemblymag.com

The Latest in the World of Assembly

Assembly Tech Online Take a stroll through ASSEMBLY magazine’s online, virtual trade show and see the latest in manufacturing technology.

2 people. 1 tool. Infinite configurations. 1 Full Adaptability The Arlink 8000’s Definite Positioning System allows easy, secure placement and reconfiguration of accessories.

With the Arlink® 8000 workstation, the possibilities are mind-boggling. A couple of people with a Phillips screwdriver can build exactly what you need. The unique Definite Positioning System®, dozens of footprint configurations, and Starter and Adder modules let you easily set up a workstation for any application. And when it’s time for a change, you’re done in a few minutes. It’s that simple. It’s that fast. Go configure.

Experience a detailed, interactive overview of the Arlink 8000 workstation’s innovative, time-saving features. Visit www.arlink6.listaintl.com

Editorial

ASSEMBLY

Whose Back Yard?

E

veryone knows NIMBY. “Not in my backyard” succinctly describes our reaction to anyone’s proposal to locate anything we find objectionable in close proximity to where we live, work or play. In the case of obsolete computers, TV sets, cell phones and myriad other electronic products discarded for recycling and reclamation, the challenge of how to safely dispose of them has become a major NIMBY issue. In a podcast last year, IBM pointed out that the fastest-growing part of the waste stream is electronic products. In 2007 alone, more than 63 million computers in the United States were traded in or thrown out, according to the Environmental Protection Agency (www.ibm.com/podcasts). IBM has long focused on recycling its own information technology products. Its take-back programs began in Europe in 1989, and IBM now offers assetrecovery programs in 57 countries. Between 2002 and 2005, the company’s asset disposition operations took in and reused more than 1.9 million machines. Panasonic, Sharp and Toshiba recently founded an organization—the Electronic Manufacturers Recycling Management Co. LLC (www.mrmrecycling.com)—to help recycle televisions and other electronic equipment they sell in the United States. The company will administer a nationwide network of 280 locations as collection centers for their products. Similarly, Sony, Best Buy, Hewlett Packard and Office Depot are creating programs for people to recycle old electronic products. Best Buy has a Tech Trade-in program in which people can bring in their used electronics and receive a store gift card. We all live on this planet together, so it behooves us to do all we can to develop practical solutions to the challenge of disposing, recycling and reclaiming parts of obsolete electronics equipment. What are your options? The Rethink Initiative (http://pages.ebay.com/rethink/index.html) brings industry, government and environmental organizations together to offer a fresh perspective and new answers to the challenge of e-waste. One of the initiative’s members, eBay, is encouraging everyone in its community of more than 157 million members to use eBay to find homes for any idle computers they might have. IBM has long suggested that you donate or recycle your old desktop instead of trashing it. If it’s less than five years old, your computer can probably be put to good use by a school or charity. Otherwise, the best option is recycling. To find a recycler near you, visit the National Center for Electronics Recycling web site, www.electronicsrecycling.org. The same suggestions apply to TV sets, cell phones and other electronic products. For example, shelters for battered women are always eager to receive cell phones because most are capable of making 911 calls, even without a service contract. Homeless shelters are a good bet for TV sets. The possibilities are limited only by your imagination and willingness to seek them out. Whose backyard? Everyone’s backyard!

®

1050 IL Route 83, Suite 200 Bensenville, IL 60106-1096 Phone 248-362-3700 Fax 630-227-0204

TOM ESPOSITO Publisher [email protected] BILL DEYOE Associate Publisher [email protected] DONALD E. HEGLAND Editorial Director [email protected] JOHN SPROVIERI Editor [email protected] AUSTIN WEBER Senior Editor [email protected] ADAM CORT Senior Editor [email protected] MIKE ROBINSON Art Director [email protected] AMANDA PODINA Marketing Coordinator [email protected] LISA WEBB Production Manager [email protected] CAROLYN PERUCCA Buyers Guide Project Leader [email protected] CINDY WILLIAMS Corporate Reprint & Trade Show Coordinator [email protected]

CORPORATE DIRECTORS Publishing Timothy A. Fausch Publishing David M. Lurie Publishing John R. Schrei Audience Development Christine A. Baloga Custom Media Steve M. Beyer Corporate Strategy Rita M. Foumia Information Technology Scott Kesler Production Vincent M. Miconi Finance Lisa L. Paulus Creative Michael T. Powell Marketing Jennifer Acevedo Directories Nikki Smith Human Resources Marlene J. Witthoft Conferences & Events Scott Wolters Clear Seas Research John Thomas

BNP Media Helps People Succeed in Business with Superior Information 6 ASSEMBLY / July 2009 www.assemblymag.com

Assemble it faster, better, for less. Find cost saving new products, technologies, and ideas at ATExpo.

EXHIBITION & CONFERENCE

September 22–24, 2009 œ˜>`Ê °Ê-Ìi«…i˜ÃÊ œ˜Ûi˜Ìˆœ˜Ê i˜ÌiÀÊUÊ,œÃi“œ˜Ì]ÊÊ­
`>Vi˜ÌÊ̜Ê"½>ÀiÊ
ˆÀ«œÀÌ®

At Assembly Technology Expo, you can see, test, and compare the complete spectrum of assembly products, technologies, and processes. ATExpo’s hands-on product demonstrations and conference sessions provide the solutions you need to improve your process, cut costs, and protect your bottom line.

"‡"
/ Ê7/\

11491_CH_ATE09

-*" -", Ê 9\Ê

Produced and managed by CANON COMMUNICATIONS LLC ££{{{Ê7°Ê"Þ“«ˆVÊ Û`°ÊUÊœÃÊ
˜}iiÃ]Ê
ʙääÈ{ÊUÊ/i\ÊΣäÉ{{x‡{ÓääÊUÊ>Ý\ÊΣäə™È‡™{™™

, -/ ,Ê/"
9Ê",Ê,

Ê 8*"Ê
Ê
--" Ê
/

ATExpo.com Please use Promo Code: AA

Automation Profiles

Systems Integrator Builds Mousetraps Better The dial assembles 900 traps per hour.

S

ince the U.S. Patent Office opened for business in 1838, it has granted more than 4,400 patents for mousetraps. Systems integrator Isthmus Engineering & Manufacturing (Madison, WI) can’t lay claim to building a better mousetrap. However, it can boast that it found a way to build mousetraps better. Recently, the company designed a system that automatically assembles and packages mousetraps. The traps are assembled on a rotary indexing dial and then transferred to an automated packaging station. In this profile, sales engineer Jane Feller rats out the system’s secrets. For more information, call 608-222-9000 or visit www.isthmuseng.com.

What are the dimensions of the finished assembly? The trap is 3.25 inches by 1.75 inches. The traps are sold in packages of two. The package is approximately 6 inches by 5 inches by 2 inches. How many parts are assembled? The trap has four parts: the top, bottom, actuator and spring. What are the parts made of? The top, bottom and actuator are plastic. The spring is a coil-steel extension spring. The packaging is card stock. What equipment feeds the parts? All four parts are fed from vibratory bowls and At the packaging station, mousetraps are loaded two-up feed tracks to pick-and-place stations, where they are placed into fixtures around the onto card stock, which is then folded, glued and placed on a belt conveyor. Photo courtesy Isthmus Engineering perimeter of the indexing dial. A SCARA robot transfers the assemblies from the dial

Trust What’s In Our Box Schleuniger’s cut and strip machines offer precise and repeatable stripping quality and a nearly unlimited range of processing capabilities.

EcoStrip 9300

OmniStrip 9450

EcoStrip 9320

PowerStrip 9500

www.schleuniger-na.com/cutstrip_am (603) 668-8117

Ready To Try?

8 ASSEMBLY / July 2009 www.assemblymag.com asb07094schl.indd 1

6/4/09 10:44:27 AM

to a linear indexer, which guides them to the packaging station. There, they are loaded twoup onto the card stock, which is then folded, glued and placed on a belt conveyor to exit the system. What methods are used to assemble the product? The parts assemble with snap-fits. The packaging is folded with a custom servo system and bonded with hot-melt adhesive. What checks or inspections are included in the assembly process? Each assembly station is equipped with photoelectric sensors to check that parts are present. Before the finished assemblies are transferred to the linear indexer, a custom-tooled unit sets and actuates each trap to ensure that it works correctly. The SCARA robot sorts rejected assemblies by category or places good assemblies into fixtures on the linear indexer. What is the production rate? The dial assembles 900 traps per hour. The packaging station produces 450 retail-ready packages per hour. How did you help the customer design the

Can the system accommodate product variants? The machine was not designed for large variants or different products without retooling. However, the packaging station is completely adjustable to accommodate variations in card stock. What was the most challenging aspect of designing and building the system? Custom folding the packaging was quite a feat. The packaging is a custom design. Maintaining perfect bend angles and alignment was done with coordinated servo and pneumatic positioning. This took a little debugging and testing on our assembly floor, but the result was a robust and accurate packaging station. A All four parts for the mousetrap are fed from vibratory bowls and feed tracks to pick-andplace stations. The parts assemble with snapfits. Photo courtesy Isthmus Engineering

product for efficient automated assembly? Some of the snap-fit lead-ins and chamfers were adjusted in their dies to accommodate automated assembly.

Editor’s note: Whether you’re a systems integrator or the inhouse automation team of an OEM, if you’ve designed a system that you’re particularly proud of, tell us about it. Send an e-mail to John Sprovieri, editor of ASSEMBLY, at [email protected], or call 630-694-4012.

ROBOTIC END EFFECTORS

Why ATI sells more Robotic Tool Changers than anyone else in the world.

Superior Fail-Safe—springless design maintains lock position in event of air pressure loss

Specially Tapered Cam—second taper produces high locking strength Locking Balls—Low-friction locking balls extend the life of the unit Lock Ring—Wide footprint of lock ring creates high moment capacity in locking mechanism

• Wide-diameter locking mechanism and specially tapered cam produce high coupling strength and large moment capacity, which eliminates gapping. • Superior mechanical fail-safe keeps tool locked to master plate in the event of air pressure loss—without a spring. This no-spring design eliminates unlock problems. • Engineered for long life—patented double-taper lock wears in, not out. Million-cycle tested for high repeatability.

www.ati-ia.com/qc/ 919.772.0115

www.assemblymag.com July 2009 / ASSE M B LY 9

NEW

& NOTEWORTHY

Robot Offers Speed, Vision Capability Cap

RED HOT Leak Detection

The M-1iA assembly robot is a lightweight, compact six-axis, parallel-link robot designed for small part handling, and high-speed picking and assembly applications. The robot can be installed in a variety of orientations and has a three-axis wrist, making it extremely flexible. It is also available with a single-axis wrist for less complicated applications requiring ultra-high speeds. The system is preconfigured for use with the new R-30iA controller. It can accommodate both a collision guard function and advanced machine vision. Its small size means it can be used in areas where space is at a premium and easily integrated into a larger assembly system. FANUC Robotics 800-iQ-ROBOT www.fanucrobotics.com

Pfeiffer Vacuum's SmartTest™ is a rugged, easy to use helium leak detector offering an Industry Best Warranty.

Monitor Higher Torques

3 year Ion Source and Filament warranty Lowest detectable leak rate for helium — 5 x 10-12 mbar l/sec High inlet pressure of 25 mbar Easily configured to your application

Pfeiffer Vacuum Inc. 24 Trafalgar Square · Nashua · NH 03063-1988 Tel. 800-248-8254 · Fax 603-578-6550 [email protected] www.pfeiffer-vacuum.com 12 ASSEMBLY / July 2009 www.assemblymag.com

High-capacity Torque Functional Test (TFT) system line includes three new models ranging from 500 Nm to 2,500 Nm. In addition to their highly accurate positioning capabilities, the new TFT units offer one percent fullscale torque sensor accuracy and 0.25 percent torque sensor repeatability. The systems offer speeds up to 200 rpm and can be tailored to an assembler’s particular needs with a full range of customized features and standard options. Each TFT includes both servomotors and precise position sensors to monitor and control torque inputs when installing fasteners, and performing pressing operations and functional tests during and after assembly. Promess Inc. 810-229-9334 www.promessinc.com

Narrow Profile Slides Carry Heavy Loads The narrow-profile Slide 2 system is constructed from a single rigid aluminum extrusion to carry heavy loads. It is only 75 millimeters wide, but capable of carrying loads of up to 250 pounds. Available with single or dual carriage options, the device can attain speeds up to 24 inches per second, depending on the motor and drive package. Other options include a stepper motor or servomotor mounted either to the side or inline. Each slide incorporates a pair of precision steel rails, bearing blocks and a 16-millimeter anti-backlash ball screw drive to ensure accuracy and durability. The slides can be ordered in lengths up to 107.2 inches. Techno Inc. 800-819-3366 www.technoautomation.com

Noncontact Gripper Handles Fragile Parts This ultrasonic gripper can pick and place solar cells, wafers and other fragile parts without ever touching them. The gripper works on the principle of near-field levitation, in which an ultrasonic generator creates a thin film of pressurized air between the gripper and the workpiece at the same time air is extracted through holes on the gripper face creating a vacuum. Basically, the vacuum holds the workpiece while the pressure created by the ultrasonic waves keeps it at a short distance, so that it and the gripper never come in actual physical contact. The distance between the ultrasonic gripper and workpiece can be between 0.05 and 0.5 millimeter. Schunk Inc. 800-772-4865 www.schunk.com www.assemblymag.com July 2009 / ASSE M B LY 13

WE FED IT One Bowl Better Than Two 䡲 By John Sprovieri Editor

S

Equipped with quick-change tooling, this bowl can feed cartridges with the open end leading or trailing. Note how the tooling to feed the cartridges in the opposite direction is stored on the bowl itself. Photo courtesy Custom Feeder Co.

Editor’s note: “We Fed It” is a regular series profiling parts feeders for automated assembly. Whether it’s a vibratory bowl, a tray feeder or a flexible robotic system, if you’ve solved a parts-feeding challenge, we’d like to hear about it. Send an e-mail to John Sprovieri, editor of ASSEMBLY, at [email protected], or call 630-694-4012.

ometimes, it’s the machine you don’t sell that wins you business. That was the case for Mike Stamm, general manager of Custom Feeder Co. (Rockford, IL). Recently, an ammunition manufacturer contacted Stamm to build two vibratory bowls to feed 9 mm pistol cartridges at a rate of 120 parts per minute. One bowl needed to feed the cartridges with the open end trailing, so an ejector groove could be machined around the cartridge body. The other bowl had to feed the cartridges with the open end leading, so the parts could be cut to length. Since both operations would be performed on the same machine, a complicated slide mechanism would switch from one bowl to the other. Stamm had a better idea. Why not build one bowl to handle both jobs? Stamm and his team built a bowl with an inside track that feeds the cartridges upright, with the open end up. As the track winds to the outside of the bowl, it encounters a set of quick-change tooling that tips the cartridges forward or backward. Two bolts hold the tooling in place. “We avoid adjustable tooling whenever possible, because we don’t want operators to dial in any parameters,” says Stamm. Changeover takes less than two minutes, and the bowl feeds 160 cartridges per minute. In another bit of clever engineering, the opposite set of tooling is stored on the bowl itself, so operators never waste time looking for it. For more information, call 815-654-2444 or visit www.customfeeder.com. A

Quality Endures. We shipped the first Alpha Series Cam Indexer on September 29, 1997. ZERO replacement cam followers have yet been shipped. FR

EE 2WARRANYEAR T Y!

BH Series Base Machine

NEW!

ED Series Shaft Output

ServoDex Roller Gear Technology

Alpha Series Table Indexer GY Series Pick & Place

Largest cam follower sizes in the industry with unmatched accuracy. 10655 State Route 47 • PO Box 4338 • Sidney, Ohio 45365 Phone: (937) 498-4901 • [email protected] www.sankyoamerica.com

14 ASSEMBLY / July 2009 www.assemblymag.com

Assembly Lines

Inventions

Mergers Forecasts New facilities Cleveland Plant First to Build ‘Green’ Engines

Hegland Retires as ASSEMBLY’s Editorial Director

Boeing: Long-term Prospects Remain Good

BENSENVILLE, IL—After nearly 25 years at the helm of ASSEMBLY magazine, Donald E. Hegland has retired.

CHICAGO—Despite the current hard times, Boeing Co. projects that in the long term, the demand for airplanes will remain strong, with airlines buying an estimated 29,000 new commercial airplanes valued at $3.2 trillion over next 20 years. In its annual market outlet report, now in its 45th year, the company also predicts that global passenger traffic will grow about 4.9 percent annually over the next two decades, and that cargo traffic to grow at an average annual rate of 5.4 percent. “While the commercial aviation industry is facing a significant downturn, it is cyclic and has a long history of declines and upturns,” says Boeing vice president of marketing Randy Tinseth. “Over the past 30 years, through both tough and good times, traffic growth has averaged more than 5 percent per year, demonstrating the resilience of the market.” According to the report, smaller single-aisle airplanes, like the Boeing 737 and Airbus A320, will represent 67 percent of all sales in terms of units. Larger twin-aisle airplanes, like the new Boeing 787 Dreamliner and the Airbus A380, will capture the largest market share in terms of investment dollars.

Ford Motor Co. has begun assembling its new EcoBoost Engine in its retooled Plant No. 1 in Cleveland. Photo courtesy Ford Motor Co.

DEARBORN, MI—Ford Motor Co. recently marked what it describes as a “key step” in its plan to provide fuel economy across its product line by beginning production of the new EcoBoost engine at its Engine Plant No. 1 in Cleveland. To facilitate the changeover, Ford invested approximately $55 million to retool the facility, which was idled in 2007. Approximately 250 employees have returned to work to build the new engines, which will be available in the 2010 Lincoln MKS and Lincoln MKT. EcoBoost engines combine turbocharging and direct gasoline injection to provide better fuel economy and reduce carbon dioxide emissions, at the same time improving performance. According to Ford, this “downsize and boost” strategy provides consumers better fuel economy in a smaller engine without sacrificing power. “This launch of the first EcoBoost engine is a significant milestone in Ford’s overall commitment to deliver affordable fuel efficiency for millions,” says Barb Samardzich, vice president of global powertrain engineering. “We’ve spent the past two years developing EcoBoost technology and now our customers will finally have the opportunity to experience what this engine delivers, the power of a V-8 with the fuel economy of a V-6.” Ford’s Cleveland Engine Plant No. 1 opened in 1951 as the company’s first engine plant in Ohio. Since then it has produced more than 35 million engines.

John Sprovieri, who joined the magazine as a senior editor in February 1997, will continue as the publication’s chief editor. Hegland joined the magazine in July 1985, and he will continue to contribute to ASSEMBLY as editorial director emeritus. Beginning in September, he’ll be writing a new bimonthly column in ASSEMBLY to share his thoughts on current events in manufacturing. Prior to joining ASSEMBLY, Hegland served as chief editor of Production Engineering magazine and publisher of Industrial Paint & Powder magazine. Before entering the publishing profession, Hegland was an engineer with NASA. He holds a bachelor’s degree in physics from Northern Illinois University in DeKalb, IL, and a master’s degree in physics from Iowa State University in Ames, IA.

Norfolk Southern Earns Logistics Excellence Award NORFOLK, VA—UPS Autogistics (Atlanta), in conjunction

www.assemblymag.com July 2009 / ASSE M B LY 15

Assembly Lines

Grow by Developing Within Eric Bigelow Industrial Engineer–Continuous Improvement Yamaha Motor Manufacturing Corp. of America Newnan, GA

~ XYZO Robotic System Automatically Identifies, Locates, Registers, and Drives t
%SJWFT
.VMUJQMF


-PDBUJPOT
1BSU

0SJFOUBUJPOT
5PSRVF t
%JGmDVMU
3FDFTTFE
)JHI



5PMFSBODF
-PDBUJPOT t
$BO
CF
7JTJPO

(VJEFE
3PUBSZ
*OEFYFE t
5IFUB
"YJT t
4IPXO
XJUI
5JMU
(JH

5BCMF
UP

PS
o
o t
7BDVVN
&YUFOE

[email protected] www.visumatic.com

859.255.7907

16 ASSEMBLY / July 2009 www.assemblymag.com

There are thousands of articles and books on promoting from within a company. There are an equal number on employee development. But how many companies actually strive for it? How many companies invest time and capital into every single employee? How many managers measure the promotability of their people and grade themselves on the outcome? Some managers believe in forced attrition, in which they remove 10 percent to 15 percent of the workforce every year to recruit new talent from outside the company. This theory does have several convincing arguments. Hiring from outside will bring with it fresh ideas and new technologies. It will bring expertise and solutions. Nevertheless, practicing this theory will not produce the long-term sustainable benefits most companies crave. It will, in fact, have an opposite effect. Sometimes hiring from outside the company is a necessity. It is good to have new talent come into the company. However, it should only be encouraged at a company’s beginning stages, or during a new production system’s design or implementation. In other words, hiring from outside should only be a necessity as a robust, healthy production system is being created. Once the system is up and running, management should make a collective effort to avoid it. How can management avoid it? The answer is, by avidly investing in employees. Many managers fail to realize that the talent they are chasing outside the company is already inside, waiting to demonstrate its value. Everyone has enthusiasm when they start a new career. Everyone wants to make a good impression and show their value to with Ford Motor Co. (Dearborn, MI), has presented Norfolk Southern Railway with its 2008 Carrier of the Year Award for overall logistics excellence in the transportation of Ford vehicles. The award recognizes superior performance in on-time delivery, damage-free handling and total customer service. Norfolk Southern transported more than 1.4 million Ford vehicles in 2008. “Ford and Norfolk Southern have had a long, mutually beneficial relationship, and this award is a testament to their commitment to excellence and customer service,” says Walter Lowe, Ford’s manager for North America vehicle logistics. In all, Norfolk Southern Railway operates approximately 21,000 route miles in 22 states and the District of Columbia, and serves every major container port in the eastern United States.

Promess Inc. Marking Quarter Century BRIGHTON, MI—Industrial pressing, sensing and torque equipment manufacturer Promess Inc. is marking 25 years in business by preparing to move ahead with yet another expansion of its office, research and manufacturing facility in Southeast Michigan. Incorporated in 1984, Promess moved into its current headquarters in 1986, subsequently expanding the facility in 1991 and again in 1998 to its present 25,000 square feet. Plans and permits for a third proposed expansion are already complete and will be implemented as market conditions improve, says company founder and president Larry Stockline. Upon completion, the upgrade will increase the facility’s

The SCHMIDT Solution their superiors. Therefore, start developing employees at this stage— SCHMIDT® keep the enthusiasm alive and keep up expectations. For Absolute ServoPress Train all employees in the company’s production system. Give Systems Press Control them improvement projects and coach them to guarantee successes. Send employees to lean seminars and schools. Invest until they are • Fully integrated, & Real Time self-contained filled with system values and theories. Invest until they have passion Feedback system and experience. Then measure them on their lean decisions and actions. Promote based on the mastery of elements designed into a • Closed loop control of ram career path. force and Creating a robust production system will naturally create a career distance path for employees. It will naturally call for employee development, • Positioning empowerment and measurables. It will give employees the enthusiasm accuracy of .0004” to learn the production system and grow within it. Management will be able to create and mold talent as it needs it. The company will then • Dynamic bending compensation have an army of lean thinkers and doers already built to its specifications and requirements. Managers will have employees who are ready • 100% quality assurance and to take on new responsibilities at a moment’s notice. verification If employees are neither challenged nor developed, their performance will eventually decline and stagnate. This is why managers so often find themselves having to resort to recruiting from the outside, because the enthusiasm of their existing employees has plummeted. ® The manager missed the window. Worse yet, without a robust system, the new recruit’s enthusiasm will also plummet over time, creating a vicious cycle that costs the company valuable time and money. Imagine having an entire workforce devoted to the company’s one, Call 1-800-959-1218 robust, lean manufacturing system, dedicated to the elimination of Visit: www.schmidtpresses.com waste. Picture every employee working to be the best and the most promotable. Imagine all your employees absorbing as much as they can from lean experts and then applying those theories every day at work. Visualize having a workforce flexible enough to handle any situation, asb01094schmidt1.indd 1 12/17/08 capable of being promoted into almost any position at a moment’s notice. Employees can and will do all this for the management team— all it takes is time and investment.

The SCHMIDT Solution

production capacity about 40 percent. Promess also has a plant in Berlin, Germany, which manufactures products for distribution outside the United States. The Promess equipment line is comprised of “intelligent” systems that both monitor and control manufacturing and assembly processes by measuring in-process assembly or functional force, position and torque to ensure that the resulting components are within specification.

Schleuniger Launches Service Products MANCHESTER, NH—Wire processing equipment manufacturer Schleuniger USA recently unveiled what it is describing

as a “new portfolio of globally structured service products,” to help its customers get the most out of their wire processing equipment. Specific products include investment and presales support, commissioning at the customer site, a preventive maintenance and extended warranty program, and new options for repair services. Regular preventive maintenance, in particular, will not only extend the life of a piece of equipment, but ensure it produces the highest quality product. The company’s maintenance service includes cleaning, lubrication, calibration, the exchange of a system’s most important wearable items and software upgrading. For additional information, visit www.schleuniger-na.com or call 603-668-8117.

SCHMIDT® ManualPress 300 Series

• Versatile, • • • • •

hand-powered operation with process monitoring Sequence/Monitor controller Electronic stroke control via clutch and brake Rack & Pinion and Toggle Press models Integrated load cell and linear scale “Poke Yoke” process verification

10:13:30 AM

For Cost Effective Assembly with 100% QC and Stroke Control

®

Call 1-800-959-1218

Visit: www.schmidtpresses.com www.assemblymag.com July 2009 / ASSE M B LY 17

Assembly in Action

Coiled Spring Pins Improve Steering Column Assembly

A

During installation, a coiled spring pin is first compressed so that it will fit easily in a hole. It is then allowed to relax once in place.

For reprints of any Assembly in Action article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.

t its plant in Hamburg, Germany, Daimler AG (Stuttgart, Germany) recently decided to further streamline its manufacturing processes with respect to one of its steering column assemblies. Specifically, the company discovered that the phosphate-coated coiled pins it was using to attach the system’s aluminum housing and gear motor were failing during installation because of the high insertion forces required. The result was an unacceptable amount of scrap and decreased productivity due to the down time required to continually fix the problem. Because the steering column was already a mature design, the hole sizes could no longer be changed without incurring unacceptably high engineering and revalidation costs. In addition, the customer had already invested in an expensive automated assembly system configured to insert the original pins within a specific force range. To solve the issue, Daimler switched to a controlled-insertion, standard-duty pin from fastener and installation equipment manufacturer Spirol International Corp. (Danielson, CT). Because of their superior quality, the Spirol coiled pins required far less insertion force than what Daimler had been using previously, thereby allowing the company to avoid damaging the columns’ housing assemblies. Spirol also recommended that the phosphate coating be removed to help cut materials costs.

18 ASSEMBLY / July 2009 www.assemblymag.com

Because the new pins provide the same shear strength as the original, they saved Daimler from having to perform a new set of validation tests. The end result was improved productivity and fewer scrapped assemblies. Once assembled, the pin, which functions like a hinge, is subject to minimal loads. This meant Daimler had the option of going with a lighterduty pin of similar design. However, doing so would have required running a full set of new validation tests, so the company chose to go with the sturdier configuration.

The fasteners help isolate the assemblies in which they are installed from shock loads and vibration. During installation, a coiled spring pin is compressed so that it will fit easily in a hole, or holes, and then allowed to relax once in place. It is this inherent flexibility that enables coiled pins to absorb wide manufacturing tolerances as well as provide selfretaining performance. In operation, the fasteners serve as a kind of “mini shock absorber,” in that they help isolate the assemblies in which they are installed from shock loads and vibration. The pins provide a uniform radial force against the surfaces of the holes in which they are installed across 270 degrees of contact. They do not require tight hole tolerances and easily lend themselves to automated installation. For additional information on pins and mechanical fasteners, call 860-774-8571 or visit www.spirol.com.

Sun Rises on New Plant for Making Solar Panels 䡲 By John Sprovieri Editor

D

awn may have finally broken for the photovoltaics industry. Design breakthroughs, government initiatives and the rising price of fossil fuels are spurring demand for products that harness the sun’s energy. Across the country, promising new companies are racing to open manufacturing facilities to take advantage of this emerging market. Ascent Solar Technologies Inc. is a case in point. In March, the company opened its new headquarters in Thornton, CO. Expected to hire some 200 people during the next two years, the facility was built to launch full-scale production of thin-film photovoltaic modules. Ascent Solar was formed in October 2005 by ITN Energy Systems, a technology incubator that has applied more than $60 million to research and development in photovoltaics over the past 15 years. Unlike conventional solar panels, which consist of silicon solar cells sealed under large, rigid glass panels, Ascent Solar’s thin-film modules are lightweight and flexible. With an efficiency of 9.5 percent, the modules can power spacecraft, consumer electronics, and residential and commercial buildings. The company began producing the modules in late 2007 at its original plant in Littleton, CO. “The most challenging thing for us was going from the R&D lab to pilot production,” says Brian Blackman, investor relations manager for Ascent Solar. “The equipment we’re installing for full-scale production is identical to the equipment we developed for pilot production. It has taken a lot of time and work to debug pilot production, but that will save time when we’re ramping up the new line.” To get its new headquarters, Ascent purchased an existing 120,000 square foot structure for $5.35 million. It then spent $10 million on renovations, adding 20,000 square feet. It spent another $110 million on capital equipment. “We upgraded the whole building—everything from the power cables to the water lines,” says Blackman. At peak capacity, the new facility will produce enough solar panels in one year to generate 30 megawatts of electricity. In contrast, the company’s pilot line can only produce enough solar panels annually to generate 1.5 megawatts. The process of making Ascent’s photovoltaic modules begins with a roll of high-temperature polyimide film, approximately 330 centimeters wide and 150 meters long. The film passes through a series of deposition steps in a roll-to-roll process. Most solar modules are made up of dozens of individual, interconnected photovoltaic cells. Ascent Solar’s modules are monolithically integrated, meaning the company skips the process of connecting

Ashutosh Misra, Ascent Solar’s senior vice president, shows off a machine for applying CIGS to a thin polyimide film in a roll-to-roll process. Photo courtesy Ascent Solar Technologies Inc.

cells. “Essentially, our process creates the world’s largest solar cell— it’s the length of the entire substrate,” explains Blackman. In the first step, a machine applies a thin layer of molybdenum to the plastic. This layer helps collect the electrons generated by the photovoltaic material. The next machine applies layers of copper-indiumgallium-diselenide (CIGS) in a thermal evaporation, vacuum deposition process. A window, or buffer, layer is deposited next, followed by a transparent conductive oxide. In the next steps—monolithic integration, screen printing and laser scribing—additional conductors are applied to the modules. After the modules are cut to length, they are laminated with a protective plastic. Finally, the finished modules are tested to see how efficiently they turn light into electricity. “Because of our highly automated manufacturing processes, we can produce the best product at a very competitive price right here [in the United States],” says Mohan Misra, founder and CEO of Ascent Solar. A Editor’s note: With all the news of bailouts, layoffs and plant closings, it’s all too easy to think every manufacturer is stuck in the doldrums. In fact, there’s plenty of good news in manufacturing—if you take the time to look. “Moving Forward” is dedicated to new or expanding assembly plants. If you know a facility that’s opening, growing, investing in new equipment, or simply going great guns while everyone else is treading water, we’d like to hear about it. Send an e-mail to John Sprovieri, editor of ASSEMBLY, at sprovierij@ bnpmedia.com, or call 630-694-4012.

www.assemblymag.com July 2009 / ASSE M B LY 19

ASSEMBLY

Power Tools

Technology Makes an Impact New technology gives impact wrenches the ability to measure torque and angle.

Cordless impact wrenches are more maneuverable than air-powered tools, but pneumatic tools are faster and more powerful. Photo courtesy Ingersoll Rand Industrial Technologies

 By John Sprovieri Editor

T

he impact wrench is hardly new. In fact, this year marks the 75th anniversary of the introduction of the impact wrench by Ingersoll Rand in 1934. That’s a good long run for any product, much less one for tightening threaded fasteners. Deanna Carter, global product manager for industrial and garage tools at Ingersoll Rand Industrial Technologies (Annandale, NJ), thinks she knows why the tool has been around for so long. “It’s so simple,” she says. “The impact wrench gives you a lot of speed and power in a small, lightweight package.” Assemblers shouldn’t confuse longevity with stagnation, however. The impact wrench on today’s assembly lines is not the same the tool that automotive mechanics have been using to bang down lug nuts for decades. New technology has made the tools lighter, quieter and more durable. Cordless models have been available for a few years now, and new technology has recently been introduced that gives impact wrenches the ability to measure and control torque and angle. As its name implies, an impact wrench delivers torque in a series of short bursts created by the impact of a swinging hammer on an anvil. The hammer is connected to the output shaft of a pneumatic or electric motor. The

20 ASSEMBLY / July 2009 www.assemblymag.com

anvil is connected to the driveshaft of the tool. When the fastener is running free, the hammer and anvil move together. When the socket encounters resistance from the fastener, the hammer rotates independently, striking the anvil once or twice with each revolution of the output shaft, depending on the tool.

“The impact wrench gives you a lot of speed and power in a small, lightweight package.” —Deanna Carter, Ingersoll Rand “If you need to drive a nail into a piece of wood, you don’t push on it with a continuous force,” explains Carter. “You pound it in with a series of impacts. The momentum of the swinging hammer drives the nail through. An impact wrench works in much the same way.” Because impact wrenches apply torque to the fastener in short bursts, reaction force is minimal, even when applying hundreds of foot-pounds of torque. This design also means that impact wrenches have a very high power-to-weight ratio. For example, the LMS 37 impact wrench from Atlas Copco Tools and Assembly Systems (Auburn Hills, MI) weighs just 6 pounds, but it can deliver as much as

352 ft-lbs of torque. These advantages make impact wrenches ideal for tightening large fasteners in products such as heavy trucks, agricultural equipment, construction machinery and railcars. Impact wrenches come in a wide range of sizes, from a 1/4-inch hex drive, pistol-grip model to a 3.5-inch square drive, two-handled behemoth. The former weighs 2.4 pounds, has a free speed of 15,000 rpm, delivers 1,500 impacts per minute, and applies a maximum torque of 250 ft-lbs. The latter weighs 599 pounds, has a free speed of 295 rpm, delivers 500 impacts per minute, and applies a maximum torque of 80,000 ft-lbs. Impact wrenches are available in pistol-grip, in-line and D-handled models. The end of the driveshaft can be hexagonal, square or splines. Industrial-quality cordless impact wrenches were introduced in 2006 and are now produced by Ingersoll Rand, Milwaukee Electric Tool Corp. (Milwaukee) and Makita USA Inc. (La Mirada, CA). For example, Ingersoll Rand offers cordless impact wrenches in 7.2-, 14.4- and 19.2-volt models equipped with nickel-cadmium or lithium-ion batteries. Drive sizes range from 1.4-inch hex to 1/2-inch square. To reduce weight, the housing is made from an engineered composite with a metal subframe. “With an air tool, you’re limited by the air hose in terms of what you can reach,” says Carter. “You also need access to a compressor. The portability of cordless tools is very attractive to a lot of manufacturers.” On the other hand, pneumatic impact wrenches have fewer moving parts than their cordless cousins and will typically be lighter and more powerful than comparably sized batterypowered tools, says Carter. For example, Ingersoll Rand’s 2900 series pneumatic impact wrench with a 3/8-inch square drive has a free speed of 10,000 rpm and delivers 1,500 impacts per minute. It weighs 2.5 pounds and

Stanley Assembly Technologies has introduced the first impact wrench with an electronic torque transducer. Photo courtesy Stanley Assembly Technologies

delivers a maximum torque of 180 ft-lbs. In contrast, Ingersoll Rand’s Model W150 14.4-volt cordless impact wrench with a 3/8-inch square drive has a free speed of 2,200 rpm and delivers 3,000 impacts per minute. It weighs 5 pounds, including the battery pack, and delivers a maximum torque of 150 ft-lbs.

A pistol-grip pneumatic impact wrench with a 1/2-inch square drive produces a noise level ranging from 89 to 96 decibels. A D-handled tool with a 1-inch square drive produces a noise level ranging from 94 to 110 decibels. In contrast, a pulse tool generates a noise level of 80 decibels, a pneumatic nutrunner with an automatic shut-off clutch proErgonomic Concerns duces a noise level of 77 decibels, and a Although impact wrenches apply a DC electric nutrunner produces a noise lot of torque with little reaction, there level under 70 decibels. are trade-offs. One is excessive noise. On Ingersoll Rand’s new Max line of impact tools, “we changed the air porting and used different materials in the exhaust to make the tools quieter,” says Carter. Another trade-off is excessive vibration. According to a 2007 study conducted by the National Institute for Occupational Safety and Health (NIOSH, Washington, An impact wrench delivers DC), the handle of an impact torque in short bursts created by the impact of a swinging wrench vibrates with an average hammer on an anvil. The acceleration of 6.6 meters per hammer is connected to the second squared. In comparison, output shaft of the motor. a pneumatic nutrunner with an The anvil is connected to the automatic shut-off clutch vibrates driveshaft of the tool. When the fastener is running free, at 2.5 meters per second squared. the hammer and anvil move A pulse tool vibrates at 2.1 meters together. When the socket per second squared. encounters resistance, the To avoid cumulative trauma hammer rotates independently, disorders, NIOSH advises striking the anvil once or twice with each revolution of the assemblers to avoid operating output shaft. Photo courtesy impact wrenches for more than Chicago Pneumatic 4.5 hours per day. www.assemblymag.com July 2009 / ASSE M B LY 21

Power Tools “Impact wrenches should not be used for high-volume assembly,” admits Hans Mandahl, product manager for assembly tools at Atlas Copco. “If you have to use an impact wrench for 8 to 10 hours per day, it could be harmful.”

Impact wrenches are ideal for tightening large fasteners in heavy trucks, agricultural equipment, construction machinery and railcars. Photo courtesy Atlas Copco Tools and Assembly Systems

New Technology Until recently, another trade-off with impact wrenches has been torque control and accuracy. In most cases, the assembler would simply hold the trigger until he judged the fastener was tight enough. Not surprisingly, the actual torque applied to the fastener could vary by 30 percent to 50 percent. However, new technology has improved the torque control capability of these tools. For example, Atlas Copco’s impact wrench has an adjustable mechanism that shuts off the tool when a preset number of impacts,

or hits, have been applied to the fastener. “You can set the dial to deliver, say, 10 hits and then shut off the air,” explains Mandahl. “That eliminates a lot of operator influence.” In the tool crib, engineers can run experiments to correlate a specific number of hits with the desired torque level. “If the torque is too low, then you increase the number of blows on the dial and measure again,” says Mandahl. Stanley Assembly Technologies (Cleveland) has introduced the first impact wrench equipped with an electronic torque transducer. Because impact wrenches apply torque in short bursts, measuring and controlling their torque electronically has been nearly impossible. Stanley found a way around the problem by applying a technology originally developed by MagnaLastic Devices Inc. (Chicago) for

% * 4 $ 0 7 & 3
/ & 8
) 0 3 * ; 0 / 4

6/*1-"$&

#&-5

#"--4$3&8
%3*7&/
"9*4

-*/&"3
.0503
"9*4 %*4$07&3
063
-"5&45
5&$)/0-0(*&4 XXXTDIVOLIPS J[POTDPN



XXXTDIVOLDPN 22 ASSEMBLY / 1July 2009 www.assemblymag.com Asb07094schunk.indd

6/15/09 2:09:22 PM

measuring torque produced by rotating shafts in vibrating machinery, such as harvesters, helicopters and winches. The technology works like this: The wrench’s output shaft is magnetized. When torque is applied to the shaft, it creates highly repeatable changes in the shaft’s magnetic field. Electromagnetic coils surrounding the shaft detect those changes and send the signals to an electronic controller. Software translates the signals into meaningful torque data that can be used for closedloop control of the fastening process. An additional sensor can be added to measure and control angle. When a preset torque and angle have been reached, the controller automatically shuts off air to the tool, says Doug Versele, global product manager for industrial and automotive power tools at Stanley. The controller has 24-volt I/O for connecting to a PLC and Ethernet ports for sending fastening data to a shop-floor network. The wrench is equipped with a headlight to illuminate the workpiece. The light turns green if the fastener has been tightened correctly; it shines red if it hasn’t.

The tool’s pin-clutch design enhances the ability of the electronics to control torque. The clutch applies torque in smaller increments than the traditional twin-hammer mechanism found in most impact wrenches. “It’s not the same level of control as a continuous-drive DC electric tool,” concedes Versele. “But you can get a Cpk of 1.67 ±10 percent on a welldesigned joint.” A

For reprints of this article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.

ASSEMBLY ONLINE For more information on power tools, visit www. assemblymag.com to read these articles:  Torque Trade-Offs.  Don’t Shut Off the Air.  Choosing the Optimum Fastening System.

The impact mechanism in Atlas Copco’s LMS series of wrenches is tightly sealed to prevent lubrication from being expelled during operation. This minimizes maintenance and increases the life of the tool. Photo courtesy Atlas Copco Tools and Assembly Systems www.assemblymag.com July 2009 / ASSE M B LY 23 ASB05094Techno.indd 1

4/20/09 3:20:02 PM

Special Report:

State of the Profession 2009

Ready for the Recovery Assemblers are worried, but cautiously optimistic.  By Austin Weber Senior Editor

T

he end is near. After enduring the most nerve-wracking economic boom-to-bust period since the Great Depression, assembly professionals finally see light at the end of the long, dark tunnel. While the automotive and housing markets remain flat, they are beginning to show signs of life. Confidence is slowly starting to return to both Wall Street and Main Street. That’s good news for assembly professionals, who are eager to start ramping up their production lines. The 2009 ASSEMBLY State of the Profession survey was conducted in early March, shortly after the controversial $787 billion economic stimulus plan was signed by President Barack Obama. However, the news at the time was bleak. New vehicle sales were down 37 percent in March. And, the average work week dropped to 33.2

hours, which was a record low, according to the U.S. Department of Labor (Washington, DC). Numerous companies announced layoffs in March, pushing the unemployment rate to 8.5 percent, the highest level in 26 years. Manufacturers in all industries have slashed their budgets in recent months. In fact, 80 percent of assemblers claim that budget cutbacks are affecting their plants, which is a 44 percent increase over last year. Another sign of the times is salary. Only 31 percent of survey respondents expect to receive a pay increase this year vs. 76 percent in 2008. Numerous individuals have experienced pay cuts, furloughs and elimination of benefits. And, an even more sobering statistic is the fact that more than half (60 percent) of respondents claim that their retirement plans have changed because of the economy. Despite enduring those hardships, assembly professionals remain relatively upbeat. Indeed 38 percent of respondents claim they are “highly satisfied” with their jobs, which is 1 percent higher than 2008. Perhaps those individuals are just happy to have a job, or maybe things are finally starting to pick up.

24 ASSEMBLY / July 2009 www.assemblymag.com

Positive Signs Several recent reports by economists indicate the latter. For instance, the National Association for Business Economics (NABE, Washington, DC) claims the recession will end soon. “While the overall tone remains soft, there are emerging signs that the recovery is stabilizing,” says Chris Varvares, NABE president. “[However], the economic recovery is likely to be considerably more moderate than those typically experienced following steep declines. “The key downside risks remain continued large job losses, no improvement in credit conditions and further sharp declines in home values,” adds Varvares, who also serves as president of Macroeconomic Advisers LLC (St. Louis). “These same forces are causing consumers to remain cautious. The good news is that economic growth [will] turn positive in the second half of this year, with the pace of job losses narrowing over the remainder of the year and employment turning up in early 2010.” Other experts, such as Robert Gordon, an economics professor at Northwestern University (Evanston, IL), agree with that assessment.

Ironically, he bases his optiLabor mism on claims for unemployment benefits. Gordon believes the peak in jobless claims, which occurred in April, typically takes place during the bottom curve of a recession. Another good indicator of economic health is corporate 24% profit. According to the U.S. Department of Commerce’s Bureau of Economic Analysis (Washington, DC), corporate profits from current production increased $43 billion in 2004 the first quarter of 2009, in sharp contrast to a decrease of $250 billion in the fourth quarter of 2008. The Institute for Supply Management (ISM, Tempe, AZ) claims that the U.S. economy grew in May for the first time in seven months. “While employment and inventories continue to decline at a rapid rate . . . there are signs of improvement,” says Norbert Ore, ISM’s chairman. The machinery and plastics industries both reported growth in May. Recent studies conducted by the Federal Reserve Bank of New York and the National Association of Home Builders (NAHB, Washington, DC) also indicate that the economy is slowly improving. For example, the number of newly built single-family homes on the market shrank to 297,000 units in April, thinning supplies to their lowest level since May 2001. “This continued reduction in the new-homes inventory helps bring supply in line with demand, which is an important step toward the market’s recovery,” explains David Crowe, NAHB’s chief economist. “Consumers are considerably less pessimistic than they were earlier this year, and expectations are that business conditions, the labor market and incomes will improve in the coming months,” adds Lynn Franco, director of the consumer research center at the Conference Board Inc. (New York). “While confidence is still weak by

earns $75,317. However, there are exceptions at both the high and low ends of the scale. For instance, 11 percent of respondents take home less than $50,000 per year, while 23 percent earn more than $90,000. But, some other statistics are more sobering. For 26% instance, only one-third (34 percent) of respondents claim they received a pay increase over the last 12 months. Most individuals were not that fortunate. Indeed, two-thirds 2009 (66 percent) of assemblers did not receive a raise. But, considering the state of the economy, that’s no surprise. According to Hewitt Associates (Lincolnshire, IL), American workers are experiencing the lowest pay raises in 32 years as companies attempt to manage overhead costs. “Many organizations are being negatively impacted by the economy,” says Ken Abosch, North American practice leader for Hewitt’s compensation consulting business. “Short-term adjustments to reduce fixed costs are required to avoid pay freezes, layoffs, or in some cases, just to survive,” Abosch points out. He says making across-the-board cuts to salary increases is one of the quickest and easiest ways for companies to lower overall costs.

Shortage Is Not a Big Concern

42% 41%

34%

2005

36%

2006

2007

2008

historical standards, as far as consumers are concerned, the worst is now behind us. “After two months of significant improvements, the Consumer Confidence Index is now at its highest level in nine months,” claims Franco. “Current conditions have moderately improved, and growth in the second quarter [was] less negative than in the first. Consumers’ short-term outlook [has] improved significantly. Those expecting business conditions will improve over the next six months increased to 23.1 percent from 15.7 percent.” Salary Statistics The typical State of the Profession survey respondent is 48 years old, has an average of 18 years experience and

More assembly plants are initiating recycling programs. Photo courtesy IBM Corp.

www.assemblymag.com July 2009 / ASSE M B LY 25

State of the Profession 2009

How Industries Compare Industry Segment*

Salary

Work Week

Computer and electronic products

$77,794

45.3 hours

Electrical equipment and appliances

$79,570

45.3 hours

Fabricated metal products

$69,304

45.0 hours

Furniture and fixtures

$78,592

44.9 hours

Machinery manufacturing

$72,539

43.8 hours

Medical equipment, devices and instruments

$74,802

46.0 hours

Plastics and rubber products

$71,618

46.1 hours

Transportation equipment

$78,936

45.8 hours

National average

$75,317

45.1 hours

*Based on North American Industry Classification System (NAICS)

Electrical equipment and appliances: includes batteries, flashlights, generators, household appliances, industrial controls, lamp bulbs, lighting fixtures and equipment, motors, switches and transformers. Fabricated metal products: includes ammunition, cans and containers, cutlery, doors, fences, firearms, hand tools, hinges, ladders, locks, metal stampings, plumbing fixtures, prefabricated buildings, springs, valves and windows. Furniture and fixtures: includes

Computer and electronic products: includes antennas, audiovisual equipment, automatic teller machines, clocks, computers and peripherals, connectors, digital cameras, flat-panel displays, laboratory instruments, loudspeakers, navigational instruments, printed circuit boards, process control instruments, railroad signaling equipment, satellites, semiconductors, smoke detectors, stereos, telephone apparatus, televisions, test and inspection equipment, transmitters, video recorders and watches.

Less than one-third (31 percent) of State of the Profession respondents expect to receive a salary increase at their next review vs. 76 percent in

2008. Assemblers in the medical device industry feel most confident about receiving an increase. Indeed, 51 percent of those individuals say

Staff Size Is Decreasing 2009 Increase

13% 67%

2009 Decrease 35%

2008 Increase 2008 Decrease

33%

2007 Increase 2007 Decrease

37% 30%

26 ASSEMBLY / July 2009 www.assemblymag.com

residential, retail and office furnishings, in addition to architectural millwork, cabinets, mattresses, shelving and window blinds. Machinery manufacturing: includes agricultural equipment, construction equipment, conveyors, food processing machinery, lawn and garden equipment, machine tools, office machines, packaging machinery, photographic equipment, printing presses, power tools, pumps and compressors, refrigeration and heating equipment, textile machinery, vending machines and welding equipment. Medical equipment, devices and instruments: includes medical diagnostic and monitoring equipment, in addition to cannulas, catheters, diagnostic test kits, dialysis aids, filters, inhalers, orthopedic implants, pumps, scalpels, stents, stethoscopes, surgical kits, syringes, tubes, valves and wheelchairs. Plastics and rubber products: includes belts, bottles, floor coverings, hoses, packaging materials, pipes and fittings, plumbing fixtures and tires. Transportation equipment: includes automobiles and automotive components, aerospace equipment, aircraft, boats, engines, motor homes, railroad locomotives and rolling stock, recreational vehicles, ships, trailers and trucks.

they expect a raise during the next 12 months. But, assembly professionals in the transportation equipment industry, which include automakers and suppliers, are less optimistic. Because of the dramatic slowdown in the auto industry, only 24 percent believe they will receive more compensation in the near future. A recent study conducted by Grant Thornton LLP (Chicago) concurs with ASSEMBLY’s findings. Jack Katz, national managing partner of Grant Thornton’s financial services practice,

claims that 58 percent of U.S. manufacturers will cut their operating costs by not giving out raises in 2009. In addition, he says 48 percent of companies will not hand out bonuses. Less than half (44 percent) of ASSEMBLY’s respondents received a cash bonus during the last 12 months, a 14 percent decrease from 2008. Most of that extra compensation was tied to overall company and plant performance, in addition to meeting deadlines for new projects and implementing successful cost reduction programs. More than one half (56 percent) of assemblers who work for companies that manufacture medical equipment, devices and instruments claim they received a cash bonus during the past year. By comparison, only 33 percent of assemblers in the plastics and rubber products industry received bonuses. Unfortunately, a large gender gap still exists in the assembly profession, but it appears to be slowly narrowing. The average salary of female assemblers (4 percent of respondents) is $64,791. Their compensation lags behind male assemblers by $10,915 or 14 percent, which is an 11 percent decrease from 2008. More than one-half (58 percent) of the women surveyed earn less than $70,000, while 57 percent of the men earn more than $70,000. One factor that accounts for some of this discrepancy is the fact that the women respondents had an average of 14 years experience in the assembly field, while men averaged 19 years of experience. In addition to gender and experience, several other factors determine average pay rates, such as age, education, location and industry. Industry experience is the biggest factor that determines compensation. Individuals with less than 5 years of experience in the assembly field (13 percent of respondents) earn an average salary of $63,488. On the other hand, industry veterans with more than 15 years of experience (57 percent of respondents) are rewarded with salaries that average $78,198.

Assembly professionals tend to be loyal employees who stay with the same company for long periods of time. In fact, 46 percent of respondents have worked at the same firm for more than 10 years, while 14 percent have been with their present employer for less than two years. Geography Determines Pay Assembly salaries vary from region

to region. Often, those fluctuations are determined by the local cost of living. Traditionally, the West (Arizona, California, Colorado, Idaho, Montana, Nevada, New Mexico, Oregon, Utah, Washington and Wyoming), which is home to only 13 percent of respondents, boasts the highest salaries in the State of the Profession survey. However, assemblers in the West also work 0.5 hour more than the national

A TRUSTED NAME.

RIVETING

NEW PRODUCTS.

Introducing two new reasons to count on Alcoa Fastening Systems. The Th Marson M MP-4V MP 4V Air/Hydraulic Ai /H d li Riveter, Ri t and d HP-3 HP 3 Professional P f i l Hand Rivet Tool. Both versatile, lightweight, and ergonomic. Both built strong for long life. New Marson tools. They’re riveting.

Bringing the Strength of Alcoa to Fastening™

afs-idg.com 800 -826-2884 www.assemblymag.com July 2009 / ASSE M B LY 27

State of the Profession 2009 average of 45.1 hours per week. The average salary in the West is $79,467, which is 5 percent more than the national average of $75,317. Assemblers in the Northeast (Connecticut, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island and Vermont) and the Midwest (Illinois, Indiana, Iowa, Kansas, Michigan, Minnesota, Missouri, Nebraska, North Dakota, Ohio, South Dakota and Wisconsin) also earn more than the national average. Assembly professionals in the South (Alabama, Arkansas, Delaware, Florida, Georgia, Kentucky, Louisiana, Maryland, Mississippi, North Carolina, Oklahoma, South Carolina, Tennessee, Texas, Virginia and West Virginia), which is home to 20 percent of respondents, earn 7 percent less than the national average. That may be one reason why many manufacturers continue to flock to the region. For instance, Volkswagen AG (Wolfsburg, Germany) is building a $1 billion assembly plant in Chattanooga, TN, that’s scheduled to open in 2011. NCR Corp. (Dayton, OH), a leading manufacturer of ATM machines, just announced that it plans to build a state-of-the-art manufacturing plant in Duluth, GA. Earlier this year, St. Jude Medical Inc. (St. Paul, MN) opened a 60,000-square-foot plant in Liberty, SC, to assemble electronics

used in pacemakers and implantable cardioverter defibrillators. This summer, MFG Galileo Composites Corp. (Sparks, NV), a leading manufacturer of radomes and reflectors, is opening a 40,000-square-foot plant in Opp, AL. In addition, the National Alliance for Advanced Transportation Batteries (Argonne, IL) recently chose Glendale, KY, as the site for a $600 million lithium-ion battery plant. Assemblers in the West are also the most confident about receiving a salary increase at their next review. Indeed, 34 percent (vs. 74 percent in 2008) of respondents say they expect a raise. However, only 27 percent of assemblers in the Midwest, home of the beleaguered auto industry, believe they’ll receive a pay increase during the next 12 months. Of course, money can’t buy happiness. Assembly professionals in the West earn more than their peers in other parts of the country, but they also tend to be less satisfied with their jobs. Only 86 percent of respondents claim to be satisfied vs. 96 percent in the South and 94 percent in the Northeast. One reason for that extra bit of happiness in the South may be due to the fact that more assemblers see their companies committing resources to assembly operations during the next three years. Indeed, 63 percent of respondents are optimistic vs. 56 percent in the Midwest. In addition, 40

Geographic Salary Variables

Midwest $75,489 West $79,467

South $70,097

28 ASSEMBLY / July 2009 www.assemblymag.com

Northeast $78,000

percent of assemblers in the South claim that their company has increased staff size during the past year, compared to only 34 percent of respondents in the Midwest. Overall, assemblers who claim to be “highly satisfied” with their jobs earn an average of $78,948, compared to $74,057 for people who claim they are “moderately satisfied.” Not surprisingly, individuals who are “not satisfied” typically do not receive cash bonuses and provide little or no input on budgeting new assembly equipment. Size Does Matter Salary and job satisfaction levels in the assembly profession are usually influenced by the size of a manufacturer. For instance, assemblers who work in companies with more than 2,000 employees tend to earn the highest average salary: $90,699. On the other hand, small manufacturers with less than 100 employees pay an average salary of $69,472.

Company Size Impacts Salary Size $90,699 $85,000

$80,000 $78,240 $75,000

$73,918 $73,894

$70,000 $69,472 $65,000

Less than 100 100 to 249 500 to 999 1000 to 1,999 2,000 or more

Number of Employees However, bigger isn’t always better, especially when it comes to compensation. Assembly professionals who work in larger companies are generally less happier than those who work for

smaller firms. Indeed, 44 percent of people who work in small companies (firms with fewer than 100 employees) claim they are “highly satisfied” with their jobs

MEDI-CAM MEDI-CAM ®

Move it smoothly…Position it perfectly…Do it Fast!!

Reliable performance everyday…24/7!

Medi-Cam Precision Link Conveyors have been medical device manufacturer's choice for more than 15 years and are designed for precision, high speed assembly and packaging of pharmaceutical & medical devices. *Complies to “Clean Room” & GAMP standards *Unmatched positional accuracy +/-0.002” *High Speed - 200 per minute index cycle rates MINI

®

Medi-Cam Part Elevators are designed to improve the pre-feed flow of individual component parts presented for assembly and installation on automated machinery. Providing controlled flow for optimal production performance and are ideally suited in feeding parts for pharmaceutical and medical devices.

* “Clean Room” & GAMP Compatible. * Allows fast production changeovers. * Ergonomic floor level part loading. Innovative Conical Hoppers for * improved part flow. * All Stainless Steel construction.

125 LITER HOPPER

PRECISION LINK CONVEYOR

SERVO LINK CONVEYOR

200 LITER HOPPER LINEAR PRECISION TRANSFER CHASSIS

PRECISION LINK CONVEYOR

CLEAN ROOM COMPATIBLE

Call Today! 973-300-0090

Call Today! 973-300-0090

ISO 9001:2000 Certified

ISO 9001:2000 Certified

www.assemblymag.com July 2009 / ASSE M B LY 29

State of the Profession 2009 State of the Profession 2008 Future Allocation to Assembly Processes More allocation to assembly 39%

OEMs

Less allocation to assembly 21%

Contract Assemblers More allocation to assembly 38%

Same/no change 40%

vs. 31 percent of respondents who work in companies with more than 1,000 employees. Assemblers who work for manufacturers with 500 to 999 employees most closely match the national “job satisfaction” average of 38 percent. Assembly professionals in the electrical equipment and appliance industry, which includes manufacturers of batteries, household appliances,

Less allocation to assembly 33%

Same/no change 29%

industrial controls, lighting fixtures, motors, switches and transformers, earn the highest salaries: $79,570. Their compensation is 5 percent above the national average of $75,317. Other industries that boast salaries above the national average include transportation equipment (5 percent higher) and computer and electronic products (3 percent higher). The medical device industry most closely

parallels the national average, with a salary of $74,802. Manufacturing engineers (44 percent of respondents) rank slightly ahead of design engineers (15 percent of respondents) when it comes to compensation. They earn an average of $159 more than their peers and they tend to work slighter shorter work weeks. However, design managers make quite a bit more than manufacturing process managers: an average of 11 percent more. Age is another important factor that often influences compensation. For instance, manufacturing engineers who are under 50 years old earn more than design engineers of the same age. Assembly professionals who are more than 60 years old typically earn the highest salaries. For example, individuals who are 60 or older earn 14 percent more than their peers who are in their 30s and 33 percent more than 20-year-olds. The average salary for assemblers in their 60s is $83,342, compared to an average of $71,938 for

Experts in

Chemical Packaging Specializing In: • Premixed and frozen two component • Difficult to package one component resins • Blending and providing modifications per your specifications

We Provide:

ISO9001:2001 – Authorized Dow Corning Repackager Contact us for quick delivery of samples and quotes toll free

866-322-8322 www.kitpackers.com

• Air free syringes and cartridges for automated X-Y-Z dispensing systems • Stock syringes and cartridges from all the major manufacturers • Maximum 5 day lead-time from receipt of materials • All materials including any special additives, fillers, or spacer beads • QA testing and certifications of many physical and performance properties with our lab equipment • Full range of other one and two component resin packaging for a exact ratio, quality mix, and precision dispense

N117 W18711 Fulton Drive • Germantown, WI 53022 • 262-253-5900

30 ASSEMBLY / July 2009 www.assemblymag.com ASB11084Ells.indd 1

10/6/08 1:17:17 PM

respondents in their 30s. Salaries also fluctuate dramatically based on type and level of education. For instance, assembly professionals with just a bachelor’s degree (57 percent of respondents) earn an average of $75,881. However, assemblers with master’s degrees (16 percent of respondents) earn an average of $12,547 more than individuals who only have 4-year college degrees (a 14 percent difference). One way to earn a higher salary is by obtaining a master’s in business administration (MBA). The ASSEMBLY survey discovered that MBAs (7 percent of respondents) make an average of 19 percent more than non-MBAs. In fact, 58 percent of MBA respondents earn more than $80,000. However, MBAs typically work longer hours than other individuals. Another way to guarantee a higher-than-average salary is to become certified. Assemblers who hold a certified manufacturing engineer (CMfgE) or professional engineer (P.E.)

designation earn an average salary 7 percent higher than noncertified engineers. Individuals with P.E.s (7 percent of respondents) earn an average of $83,372, while CMfgEs (5 percent of respondents) make $78,604. Happiness Counts Most respondents claim to be satisfied with their jobs, but a closer look at the data reveals some differences. For example, manufacturing engineers tend to be happier than design engineers. Indeed, 34 percent of manufacturing engineers claim to be “highly satisfied” vs. 28 percent of design engineers. The happiest assemblers work in the fabricated metal products industry, where 49 percent of respondents claim to be “highly satisfied” with their jobs. In contrast, only 24 percent of assemblers in the plastics and rubber products industry are “highly satisfied.” Assembly professionals who work for contract manufacturers are 6 percent happier than their peers who work for OEMs.

Job satisfaction can be defined many different ways. But, here’s what a few respondents had to say: “Each day represents a new challenge, and the constantly changing business environment requires always staying on your toes,” says a plant manager in the medical device industry who is satisfied with his job. “I am in a position where I am able to make decisions and changes with minimal outside influences,” adds a manufacturing engineer in the electrical equipment and appliance industry. “I work for a great company, with good people and a supportive environment for education and improvement,” notes a manufacturing engineer at a transportation equipment manufacturer. “We make interesting products and there are some challenging production processes that are fun to ‘lean out.’” “I have direct control over expenditures and policies that impact operational performance,” says a design

www.assemblymag.com July 2009 / ASSE M B LY 31 asb06094dymax.indd 1

5/5/09 9:55:33 AM

State of the Profession State of the2009 Profession 2009 Actions Taken Because of Economy 86%

Layoff employees

easy • accurate • automatic

ALL NEW

Reduce workweek hours

59%

Mandatory pay cuts

DSP Sensor

The Ultimate in Handheld Laser Profilers

Run it in Standalone Mode

•No cable, no tether to an external device •Use as a data collector or Go/No-Go Gage •View and save data •Integral battery 4 hour run time •Weighs 20 ounces with battery

Eliminate 401(k) contributions

30% 23%

engineer in the computer and electronic products industry. “Therefore, I am allowed to create my own strategies that facilitate achievement of company objectives.” “I work for a great small company and I enjoy what I do,” explains a manufacturing engineer in the fabricated metal products industry. “I wear many hats and that gives me great opportunity to use the skills that I have.” “It is enormously gratifying to see our equipment in use in operating rooms, helping to make a positive difference for sick patients,” says a design engineer at a medical device company. However, some respondents are less

Or Use it as a USB Device With Your Laptop or Tablet PC •Enhanced graphics and data analysis •Automatically save every scan •Run inspection routines •Compare results from different algorithms on the same scan

www.origintech.com 256-461-1313

32 ASSEMBLY / July 2009 www.assemblymag.com

satisfied with their jobs. “Upper management seems out of touch with actual product demands and part shortage constraints,” laments a manufacturing engineer in the machinery manufacturing industry. “China is right on our heels,” gripes a design engineer in the furniture and fixtures industry. “We need to get more advanced, but we are not doing it quickly enough.” “The economic downturn, combined with reduced resources and an increased workload, leave me overwhelmed, underpaid and not appreciated,” adds a plant manager in the plastics and rubber products industry.

Survival Strategies Differ by Industry When the economy soured late last year, manufacturers reacted differently. More than three-fourths (77 percent) of the 2009 State of the Profession survey respondents said they reduced inventory. Other popular strategies included tightening the supply chain (65 percent) and implementing improvement projects or holding kaizen events (60 percent). Assemblers have also increased lean training (52 percent), customer dialogue (49 percent), equipment maintenance (46 percent) and line rebalancing (41 percent). Inventory reduction is more prevalent in the transportation equipment industry (84 percent) and less critical in the computer and electronic products industry (69 percent). Transportation equipment manufacturers also prefer line rebalancing (58 percent), while equipment maintenance is more common in the fabricated metal products industry (56 percent). On the other hand, customer dialogue is more popular in the plastics and rubber products industry (68 percent) than in the medical device industry (37 percent). Plastics and rubber product manufacturers are also more eager to conduct kaizen events (76 percent) than their peers in the machinery manufacturing industry (55 percent). Large companies are more willing to reduce inventory or invest in lean training. For example, 66 percent of plants with 1,000 or more employees have engaged in training activity recently because of economic conditions. In contrast, only 45 percent of manufacturers with less than 100 employees have turned to lean lessons.

Your Global Distributor of Adhesives, Sealants and Assembly Equipment

“I started working for a small, profitable automotive parts supplier that built its own assembly equipment,” says a Electronic Assembly manufacturing engineer in the transporta& Protection tion equipment industry. “The company Thermal Management was recently bought by a big European Solutions firm that gutted the operation and moved assembly operations to Mexico. The peoUV Curing Systems ple who hired me are long gone.” & Accessories “Individual performance is based on overall company performance, Dispensing Equipment which always seems to never be good & Surface Preparation enough,” reports a design engineering manager in the fabricated metal products industry. “Quality and manufacturing engiellsworth.com/Assembly.html neers take a back seat to design engineers,” says a manufacturing engineer in the electrical equipment and appliance field. “Engineers in general are considered only one step above a technician.” ISO 9001:2000 “My company suffers from poor organizational objectives, communiVisit our website and chat with the Glue DoctorTM about an adhesive assembly solution. cation and leadership,” adds a manuwww.ellsworth.com 877-262-6029 facturing engineer in the transportation equipment industry. “Roles and responsibilities are poorly defined and are not measured.” 1 5/18/09 Widespread budget cutbacks asb06094ells.indd are having a huge impact on job satisfaction. Unfortunately, it’s a problem that affects assemblers who work for both large and small manufacturers. For instance, 67 percent of respondents at small manufacturers (companies with 100 or less employees) claim that budget cutbacks are affecting their job vs. 86 percent of respondents at large manufacturers (companies with 2,000 Micro-Percussion Scribing Laser Marking or more employees). Assemblers in the transportation equipment industry (88 percent), which Contact us for in-plant includes automakers and auto part supanalysis and demos. pliers, are the most concerned about budget cutbacks. That’s not surprising, since Chrysler and General Motors recently declared bankruptcy. Even Tag Marking 2D Coding automakers such as Honda and Toyota & Reading have scaled back production. 800-394-9101 Not surprisingly, respondents in the Technifor, Inc. medical device industry (66 percent) are Tel. 704-525-5230 www.technifor.com less concerned about budget cutbacks. Fax. 704-525-5240 Assemblers in that field are much more e-mail: [email protected] UID Compliant concerned about issues such as keeping

Technifor Direct Part Marking and Traceability

10:31:52 AM

www.assemblymag.com July 2009 / ASSE M B LY 33 ASB06074Technifor.indd 1

5/3/07 10:59:44 AM

State of the Profession 2009

The Harsh Realities of a Slow Economy There have been many casualties of the recent economic collapse. Unfortunately, layoffs are often the first way companies react to sluggish sales and lack of demand. When the economy turned south late last year and early this year, more than threefourths (86 percent) of 2009 State of the Profession survey participants experienced the stress of layoffs. Other cost-cutting activities included reduced hours (59 percent), mandatory pay cuts (30 percent) and elimination of 401(k) contributions (23 percent). Industries that have been hardest hit by layoffs include plastics and rubber (91 percent), computer and electronic products (90 percent) and machinery manufacturing (88 percent). The medical device industry has been least affected, with only 77 percent of assemblers citing layoffs. Assembly professionals in the Midwest have been the hardest hit, with 73 percent of respondents reporting reductions in the overall size

up with state-of-the-art technology and making new technology work. Because of the economy, many assemblers believe their plants will be investing in less capital equipment in the near future. When asked, “How do you see your company committing resources toward improving assembly operations during the next three years?” 21 percent said “less resources” vs. 13 percent in 2008. The two industries that are most bullish about committing resources to new production equipment include plastics and rubber products

of their assembly operations. The most stability is on the West Coast, where only 60 percent of assemblers claim they work in plants that have experienced headcount reductions. Mandatory pay cuts have affected the medical device sector (41 percent) the most, while that action is less common in the electrical equipment and appliance industry (23 percent). Reductions in hours are more common in the furniture and fixtures industry (88 percent), which has been hard hit by the slump in housing and construction, and least common is the medical device field (41 percent). Large manufacturers are more likely to mandate pay cuts. For instance, 40 percent of plants with 2,000 or more employees have cut wages within the last year because of the economy. By comparison, only 26 percent of manufacturers with less than 100 employees have slashed their payrolls. However, large companies are less likely to eliminate 401(k) contributions. Only 19 percent of large manu-

manufacturers (56 percent) and medical device manufacturers (53 percent). Less Time to Complain Because of cutbacks, assembly professionals are spending less time on the plant floor these days. In fact, 73 percent of respondents currently work more than 40 hours a week (vs. 88 percent in 2008). The national average is 45 hours, which is one hour less than in 2008. Assemblers in the medical and plastics industries work the longest days,

Response to Economic Conditions 77%

Reduce inventory 65%

Tighten supply chain 60%

Improvement projects/kaizen 52%

Lean training Customer dialogue

49% 46%

Equipment maintenance Rebalance assembly lines

41%

34 ASSEMBLY / July 2009 www.assemblymag.com

facturers have taken that route vs. 25 percent of small firms. If the poor economy continues, more manufacturers may be forced to suspend their employer 401(k) match to cut operating costs. According to Hewitt Associates (Lincolnshire, IL) companies can save millions of dollars by eliminating the practice for just one year. “A typical large company can see savings of $25 million a year,” says Pam Hess, Hewitt’s director of retirement research. “The average midsized company can save more than $10 million, and the average small company can save nearly $2 million annually. “Companies are making difficult decisions to keep their bottom line in the black, and the employer 401(k) match is one of the costliest retirement expenditures they sustain in a given year,” adds Hess. “Cutting this benefit to reduce costs is a much less drastic action than eliminating jobs or reducing salaries.”

with a weekly average of 46 hours. At the other end of the spectrum, respondents who work in the machinery manufacturing industry put in an average of 43.8 hours per week. However, assembly professionals who put in longer hours tend to earn higher salaries. For instance, individuals who work an average of 46 to 50 hours a week earn an average of $81,806. Individuals who typically work less than 40 hours a week earn $68,238. Corporate managers claim to have the longest work weeks: an average of 46.8 hours. By comparison, design managers average 46.7 hours, followed by manufacturing managers (45.7 hours), manufacturing engineers (44.6 hours) and design engineers (44.1 hours). Unfortunately, the trend toward shorter weeks is expected to continue during the next 12 months, with 11 percent of assemblers claiming that their average work week will decrease vs. 6 percent in 2008.

2D and 3D File Downloads available at www.weissna.com

n? Call us!

n? More Inform atio Assemblers in the South and West plan to work more than their peers in 8 8 8 W E IS S N A other regions. For instance, 31 percent of respondents in those parts of the United States believe the hours they The Direct Alternative! spend at work each week will increase during the year ahead. On the other hand, only 26 percent of assemblers in Technology that inspires SS the Midwest and Northeast expect to WEI work longer hours. The HP140T direct drive, linear motor pick and place. Assembly professionals who work Reliable. Precise. WEISS for smaller manufacturers plan to spend more time at work than their counter• Extremely fast, highly dynamic movements. parts in larger companies. Almost one• Freely programmable in both axes third (32 percent) of respondents who • Utilizes direct drive, linear motor technology in both the work for manufacturers with less than horizontal and vertical axes 50 employees expect to work more • Very compact, slim design hours per week in the next 12 months. • Fast acceleration up to 40m/s 2 However, only 20 percent of assem• Positional accuracy of 0.02mm and repeatable to 0.01mm HP140T Direct Drive blers who work for companies with • Complete, easy to integrate system with full controls and software more than 1,000 employees foresee longer work weeks ahead. WEISS North America, Inc. | 3860 Ben Hur Avenue | Willoughby, OH 44094 More than half (52 percent) of Phone: +1 888 WEISSNA (888-934-7762) | Fax: +1 440-269-8036 respondents said mounting time [email protected] | www.weissna.com constraints will affect their ability to do their jobs during the next 12 months. Time constraints will also have a bigger impact on assemblers 1 6/15/09 who work in large companies. asb07094weiss.indd For instance, 64 percent of assembly professionals who work for companies with 2,000 or more employees will be affected by time constraints vs. only 44 percent of respondents in companies with less than 50 employees. Time constraints will cause the most stress on assemblers who work in the transportation equipment industry (57 percent) and the computer and electronic products industry (55 percent), who are under intense pressure to launch new products and meet deadlines for projects. However, for the first time in years, a shortage of skilled labor will not be a major constraint or barrier in assembly plants. Only 26 percent of respondents cited this as a challenge vs. 42 percent in 2008. Concern over finding assemblers is greatest in the fabrication metal products industry (33 percent) and lowest in the medical device industry (17 percent).

4:11:53 PM

www.assemblymag.com July 2009 / ASSE M B LY 35

State of the Profession 2009 Is an Advanced Degree Worth It? $91,247

MBA degree

$88,427

Master’s degree

$75,881

Four-year degree

$65,758

High school diploma

Factors Contributing to Competitive Advantage 71% 69% 67% 59% 43% 39% 36% 36% 34% 20%

Green Movement Is Growing According to the State of the Profession survey, green manufacturing activity continues to increase in various industries. In this year’s study, 57 percent of respondents claim they are involved in green or sustainability initiatives vs. 46 percent in 2008. Actions include everything from plantwide recycling programs to installing new energy-efficient lighting systems. Green activity is most common in the transportation equipment industry, where 69 percent of assemblers work in plants that have implemented environmental programs. For instance, General Motors Corp. (GM, Detroit) is involved in an ambitious effort to reduce the environmental impact of its worldwide manufacturing operations. One goal is to make 50 percent of the automaker’s plants landfill-free by 2010. More than 50 GM plants have already reached that goal, which means that more than 800,000 tons of waste is diverted from landfills each year. Facilities achieve landfill-free status when all production waste or

36 ASSEMBLY / July 2009 www.assemblymag.com

garbage is recycled, reused or converted to energy. At GM’s landfill-free plants, more than 95 percent of waste is recycled or reused, while 4 percent is converted to energy. Six GM plants in the United States use landfill-gas to fire boilers or generate electricity. “A big part of being landfill-free is effective recycling,” claims Elizabeth Lowery, GM’s vice president for environment, energy and safety policy. “Not only does this intensive focus on recycling help the environment, it helps the company’s bottom line.” For example, as a result of GM’s global recycling effort, scrap metal sales generated more than $1 billion in revenue in 2008. In addition to steel, the automaker recycled 17,000 tons of wood, 20,000 tons of cardboard and 4,000 tons of plastic. Assemblers in the electrical equipment and appliances (61 percent) and computer and electronic products (55 percent) industries are also actively engaged in green programs. For instance, IBM Corp.’s facility in Poughkeepsie, NY, the recipient of ASSEMBLY’s 2008 Assembly Plant of the Year award, is a good example

of a manufacturer that is committed to protecting the environment. The 315,000 square foot high-end server plant serves as a pilot site for IBM’s new Green Sigma initiative, which is based on Six Sigma. The goal of Green Sigma is to apply principles of energy and water usage to lower environmental impact, increase efficiency and reduce costs. Disassembly and remanufacturing play an important role in the day-to-day operations of IBM’s Poughkeepsie plant. During the last six years, the plant has reused more than 11 million parts. More than 1,450 high-end systems have been recovered, refurbished and reused, while more than 25,000 metric tons of metal have been recycled. Large manufacturers (companies with 2,000 or more employees) are more likely to be involved with green initiatives. For example, 64 percent of assemblers in that category claim they have implemented sustainability programs at their plant during the last 12 months, compared to only 39 percent of small manufacturers (companies with fewer than 50 employees). Survey Methodology ASSEMBLY magazine would like to thank all the respondents who participated in its 14th annual State of the Profession survey. The survey was conducted online in March 2009 by Clear Seas Research (Troy, MI). All readers with e-mail ASB09064Qualbear.indd addresses were contacted electronically and encouraged to click a special hot link to the online questionnaire. The charts and tables in this report highlight the major data gleaned from the survey responses. On some of the questions, the response rate does not equal 100 percent due to rounding or surveys that contained one or more unanswered questions. In cases where multiple responses were allowed, the total may exceed 100 percent. Special thanks to Erin Taylor, Vince Schneider and John Thomas for their assistance with online survey design, Electric & Air Supply distribution and tabulation. For more Systems information on this study, please contact [email protected] or 248-786-1659. A

1

8/14/06 3:47:45 PM

Ergonomic Workplaces and Assembly Lines Conductix-Wampfler has one critical mission: To supply manufacturers with a wide range of safe, ergonomic overhead energy supply and material handling solutions for assembly lines and work cells. Our custom systems include the right mix of tool transporters, tool balancers, and overhead electric/air supply systems to keep your assembly lines running at peak efficiency. Our rugged, low maintenance products are time-tested in demanding environments and backed by a worldwide sales and service network.

Equipment Carriers

Contact us today with your system requirements!

ASSEMBLY ONLINE Find more salary statistics at www.assemblymag.com!

Tool Transporters Balancers

Conductix-Wampfler | 8091 Production Drive | Florence, KY 41042 Tel: (800) 326 2899 | Fax: (859) 814 2110 [email protected] | www.conductix.com

www.assemblymag.com July 2009 / ASSE M B LY 37

ASSEMBLY

Adhesive Bonding

Adhesives for Trailer Assembly Structural adhesives help assemblers of trucks, trailers, buses and other specialty vehicles reduce costs, boost throughput and improve aesthetics.

M

anufacturers of specialty vehicles, such as trailers, truck bodies, buses and construction machinery, are increasingly using adhesives and sealants to assemble frames, panels, booms and cabs made of metal, plastic and composites. By building these components with adhesives and sealants instead of welds, threaded fasteners or rivets, engineers

fasteners were used to provide structural stability. Some adhesive applications on our trailer have already been tried and tested in the field. However, we also tried many new applications for adhesives and sealants. The end result is a tougher, more reliable, better-looking trailer that cost less to build than a conventional model. Step by Step Bonding bed to frame. In traditional trailer construction, the floor is attached to the frame using mechanical fasteners,

We constructed a work trailer almost exclusively using adhesives and sealants.

Henkel engineers assembled this trailer almost entirely with adhesives and sealants.

 By Brian Noonan Application Engineer Henkel Corp. Rocky Hill, CT

can reduce assembly costs, increase throughput, distribute stress more uniformly and improve aesthetics. To prove the efficiency, durability and cost-effectiveness of adhesive assembly, we acquired a trailer frame—7 feet wide and 10 feet long—and constructed a work trailer almost exclusively using adhesives and sealants. The few fasteners that did make it into the trailer were used to temporarily hold components in place while the adhesives cured. No

38 ASSEMBLY / July 2009 www.assemblymag.com

a time-intensive process that leaves the trailer susceptible to water damage. In our project, we bonded the wood floor to the frame using Loctite 5570, an elastic adhesive and sealant that distributes the load evenly over the entire frame and prevents water from leaking in through the floor panels. Only four screws per panel were required to install the entire floor. All totaled, we installed the floor in just 10 percent of the time that would have been necessary had we used fasteners alone. Loctite 5570 is a one-part adhesive based on a modified silane polymer.

The adhesive cures by reacting with atmospheric moisture. Skin formation and curing times depend on humidity, temperature and joint depth. Under normal conditions, the adhesive develops functional strength in 24 hours and fully cures in seven days. This odorless, noncorrosive adhesive does not contain solvents, isocyanates, silicones or polyvinylchloride. Besides wood, it adheres to stainless steel, galvanized steel, aluminum, glass, fiberglass and plastics. It is compatible with most paint formulations. Resistant to ultraviolet radiation, the adhesive can be used for both interior and exterior applications. Bonding skins to frame. The sheetBy bonding the skins to the frame with adhesive, 90 percent fewer fasteners were needed for metal skin covering the sides of a trailer assembly, resulting in a better looking, stronger, more leak-resistant trailer. The same material was are usually riveted or bolted onto the used to bond the door and roof skins. frame. Instead, we used two fast-fixturing polyurethane or silicone caulks seal Loctite 5510 is a one-part adhesive structural acrylics: Loctite H4500 and gaps and prevent water penetration. based on a modified silane polymer. H8600. During the cure process, we These sealants work well, but they will Free of isocyanates, solvents and used screws to fixture the skin in place. yellow over time and do not last long in silicones, this low-odor, highly flexible By bonding the skins to the frame with the harsh environment of the road. sealant resists vibration, movement and adhesive, 90 percent fewer fasteners On our trailer, we used Loctite 5510 impact. Because it is impervious to UV were needed for assembly, resulting in to seal gaps in the frame and all the light, the sealant will not degrade or a better looking, stronger, more leak- skins, including the door and roof. Like crack over time. It fixtures quickly and resistant trailer. This same process the adhesive we used to bond the floor, can be color-matched to the skins for was used to bond the door and roof seamless assembly. skins. The adhesive cures by reacting Loctite H4500 is a highly with atmospheric moisture. It thixotropic, two-part methacrylate develops functional strength in 24 adhesive for bonding metals, such as hours and fully cures in seven days, steel, stainless steel and aluminum. but these times can be shortened by It also bonds epoxy-coated metal, increasing exposure to moisture. sheet-molding compound and many Bonding and sealing panel plastics. The adhesive bonds to trim. The panel trim located around metals without a primer. It contains the trailer’s frame was bonded using a corrosion-inhibiting additive to Loctite H4500 and 5570. Panel trim ensure long-term bond durability is normally riveted in place, then even when exposed to moisture. sealed with polyurethane or silicone Mixed at a ratio of 10-to-1, the caulks. The adhesives in our project adhesive reaches fixture strength in simultaneously bond and seal trim 15 to 20 minutes at 70 F. materials, even in critical areas such Loctite H8600 is two-part as wheel wells. While fasteners were methacrylate for structural bonding still needed to help secure the panel of galvanized steel. Mixed at a ratio trim, the use of adhesive reduced the of 2-to-1, it reaches fixture strength number of fasteners by 90 percent in 55 minutes at 72 F. This toughened and shortened assembly time by 40 adhesive has a high peel strength. A Usually, the trailer floor is attached to the frame using percent. thick material, it can be applied to mechanical fasteners. Henkel engineers bonded the Bonding diamond plate and wooden floor panels to the frame using a one-part vertical surfaces without sagging. modified silane polymer adhesive. The engineers installed nose to skins. On a traditional Seam sealing the frame the floor in just 10 percent of the time that would have trailer, the diamond plate is riveted and skins. On standard trailers, been necessary had they used fasteners. onto the trailer skin, while the nose www.assemblymag.com July 2009 / ASSE M B LY 39

Adhesive Bonding

On a traditional trailer, diamond plate is riveted onto the skin, then sealed with caulk. Henkel engineers bonded the plate using a methacrylate adhesive, eliminating mechanical fasteners altogether. The adhesive unitized the assembly and avoided the possibility of rattling.

is bolted or riveted in place, then sealed with caulk. On our trailer, the diamond plate was bonded with Loctite H4500, eliminating mechanical fasteners altogether. The adhesive unitized the assembly, eliminating any potential for rattling and producing a higher quality appearance.

Ordinarily, this galvanized steel bracket would be secured to the trailer wall with more than 200 screws. Instead, it’s bonded in place with a structural methacrylate adhesive. Assembly time was cut by 70 percent, and fastener count was reduced by 90 percent.

For the nose assembly, we used the same structural adhesive to bond and seal the nose to the skins, eliminating rivets. Because the nose assembly on our trailer came with predrilled holes, screws had to be inserted to prevent leakage. Still, bonding reduced assembly time by 20 percent and fastener count by 30 percent.

679 METRIC KNOBS for a cleaner environment

RoHS

COMPLIANT

In the future, the nose assembly could be redesigned to eliminate predrilled holes, thereby eliminating the need for fasteners. Bonding internal brackets. Most trailer interiors have galvanized steel brackets for tying down cargo. Ordinarily, we would have secured the

INDUSTRIAL ROBOTS SR-SERIES small cartesian robots are suitable for high-speed applications up to 2,000mm/sec, high precision up to ±0.02 (±0.005mm), and low noise.

 Low Vibration  Easy Maintenance Request your free catalog

 High Flexibility REQUEST

FREE CATALOG TOTAL AUTOMATION SYSTEMS

All Metric Small Parts

T. 516.302.0152 F. 516.302.0153

www.amsp.biz

120 SYLVAN AVE SUITE 301 ENGLEWOOD CLIFFS NJ. 07632 www.saejongusa.com • [email protected] TEL:1-201-944-0996 • FAX: 1-201-944-2999

40 ASSEMBLY / July 2009 www.assemblymag.com ASB06094SAEJONG.indd 1

5/6/09 10:14:19 AM

bracket plate to the trailer walls using two screws per frame member. The bracket itself would have been secured to the plate using 200 screws. Instead, we used Loctite H4500 to bond both the plate and the bracket. As a result, we needed only one screw per frame member to fixture the bracket plate, and we needed just 20 screws to install the bracket. Assembly time was 70 percent faster using adhesives, and stress is distributed evenly along the length of the bracket, making it more durable. Adhesive bonding reduced fastener use for this application by 90 percent. Threadlockers for miscellaneous hardware. For the limited number of threaded fasteners on our trailer, we applied Loctite 2033 threadlocker to prevent vibrational loosening and seizing. This medium-strength gel adhesive locks and seals threaded joints ranging from 0.25 to 1 inch in diameter. It cures in the absence of air between close-fitting metal surfaces. It resists most chemicals, liquids and gases.

exterior of the trailer is decorated with graphics that were applied without concern for the placement of metal fasteners. As of January 2009, the trailer has logged 7,000 miles and experienced no problems with structural integrity or leakage. In early February, the trailer started a tour of manufacturing locations along the East Coast. For videos of each step of this assembly project, visit www. gluemytrailer.com. A

The sheet-metal panels of this trailer were bonded to the frame with a two-part methacrylate adhesive. The material has a high peel strength and excellent resistance to ultraviolet radiation.

The Results The trailer was completed in April 2008. Since then, it’s been on the road, hauling a motorcycle and an all-terrain vehicle throughout the country. The

For reprints of this article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.

ASSEMBLY ONLINE For more information on adhesive bonding, visit www.assemblymag.com to read these articles:  Adhesives & Automobiles.  Adhesives for Structural Metal Bonding.  AIA: School Bus Learns Adhesive Lesson.

Tool Certification according to ISO 5393

SCHATZ®-TEST Automatic torque-tool certification system. Increase Quality Reduce testing costs • Torque-tool certification on-site • Complete tool database • Automatic test planning

7HEREINDUSTRYGOESFORGLOVES

… or ask for our service… We complete torque tool certification for you – on-site! • Test planning • Certification by trained personnel • Due date determination • Complete documentation • Automatic reminders • Equipment calibrated traceable to national standards

Call today: (248) 369-8661 SCHATZ USA Inc. Holly, MI 48442 [email protected] www.schatz-usa.com

9OURSOURCEFORGLOVESINDUSTRIALGLOVES ONLINECOM   

www.assemblymag.com July 2009 / ASSE M B LY 41

Advertisement

ASSEMBLY

Product Review This special advertising section is your opportunity to quickly review assembly equipment, tools, components and services that you can use to make your product assembly operations more productive and profitable. Check out the features and performance data, then pick up the phone to place an order or go to www.assemblymag.com and click on ‘Product Reviews’.

Swivel Fitting Features Captured O-ring Seals Swivel Fittings alleviate the problem of tube alignment and rotation commonly found when using fixed barb fittings. The unique design, Patent #4,496,204, allows for 360° rotation and incorporates captured double o-ring seals to prevent leakage. The fittings are available in black nylon or clear polypropylene. Five o-ring compounds are featured: Buna-N, Ethylene Propylene, Silicone, and Viton. Air Logic

262-639-9035 800-558-5950 [email protected] www.air-logic.com

SAS Automation Automating Packaging or Palletizing? End Effectors, EOAT (end-of-arm tooling) for all makes of robots. Modular systems reduce robot wear. Get a grip! components for heavyweight applications. GRIP IT!—for lightweight applications, nip it!—spruce nippers. Custom grippers, CNC degaters, Insert Mold Tools. USA, Canada, Mexico, Europe,. Made in USA. ISO 9001:2000. SAS Automation Ltd. 1200 S. Patton St., Xenia, OH 45385 888-SAS-EOAT 888-727-3628 Fax: 937-372-5555 [email protected] www.sasgripper.com

The World’s First Thermal Spot Curing System The iCure™ AS200 is a revolutionary inline fiber optic system that provides heat by Infrared radiation in a portable unit, delivering faster and stronger cures than traditional methods. The iCure thermal spot curing system is tailor-made for automated manufacturing processes requiring rapid adhesive curing and localized heating of bonded assemblies. IRphotonics T 514-345-6982 x 230 M 401-699-3553 www.irphotonics.com Ruben Burga, [email protected]

42 ASSEMBLY / July 2009 www.assemblymag.com

Paste Brazing & Soldering Alloys Fusion Paste Alloys deliver all the ingredients for a strong, void-free brazed or soldered joint in one deposit. Finely atomized filler metal, proper flux, and a neutral binder are blended into a homogeneous mixture. No more handling of caustic fluxes. Combined with dispensers and automatic machines, these pastes can transform your operation by reducing costs and improving joint quality. Fusion Inc. Willoughby, OH 800-626-9501 440-946-3300 [email protected] www.fusion-inc.com

BIG GUNS! Gage Bilt proudly announces the release of its GBP2630 Hydraulic Installation Tool. Attached to a power unit, it generates 56,000 lbs (249kN) of force to install 7/8 Huckbolts® and LD Avdeloks®. Gage Bilt also manufactures tools to install 1/2, 5/8 & 3/4; 12MM, 16MM & 20MM HP bolts. When you need 40,000 lbs of clamp contact Gage Bilt – Tough Tools for Tough jobs! Gage Bilt 44766 Centre Court Clinton Twp, MI 48038 586-226-1500 Fax 586-226-1505 [email protected] www.gagebilt.com

Advertisement

HIGH-TORQUE MINIMAT®-E Screwdrivers The electric Minimat-E Screwdriver series has been expanded to include high-torque models in inline-, pistolgrip-, and anglehead designs! The features are identical to the well-know low-torque series 䡲 Freely-programmable 䡲 Torque + angle monitoring, processing and display 䡲 Low maintenance 䡲 Ergonomic housing material and nonslip grip 䡲 Push-to-start, lever-start, stationary – may be attached to a Screwfeeder DEPRAG, Inc. 640 Hembry Street Lewisville, TX 75057 972-221-8731 Toll Free: 800-433-7724 Fax: 972-221-8163 [email protected] www.depragusa.com

Rotary Dampers Minimize noise, shock, and safety hazards. Soft and smooth motion enhances functionality and provides that touch of quality. Use on computer hardware, flip top phones, lids, access panels and more. 19 new series introduced. ACE Controls Inc. Farmington Hills, MI 800-521-3320 248-476-0213 Fax 248-476-2470 [email protected] www.acecontrols.com

Energize your Grip Turnkey Production Machines Fusion Systems Group draws upon over 50 years of assembly expertise to build turnkey systems that provide years of cost-efficient production. Assembly Machines, Material Handling, Welding, Robotic Dispensing, etc. From concept to installation, we accept Total Responsibility for all aspects of your system. Let us solve your manufacturing process problems. Contact us today for a quotation on your next machine or automation project. Fusion Systems Group 440-946-3300 800-626-9501 [email protected] www.fusionsytemsgroup.com

Gloves Online, Inc. P.O. Box 4468 Cary, NC 27519 http://industrial.gloves-online.com

New Autobonder 2101 Liquid Dispenser The Autobonder 2101 can dispense a wide variety of liquids with a range of viscosities. The included foot pedal switch and syringe holder allows for hand-free operation. The easy-to-use, six-function digital timer features accuracy to .01 seconds. The Autobonder 2101 utilizes disposable syringes that can utilize a wide range of disposable needle sizes. Hernon Manufacturing, Inc. 800-681-0004 Fax: 407-321-9700 www.hernon.com

Form-fitting coated seamless knit gloves are the newest industrial safety gloves available. Gloves-Online.com stocks the newest models, widest selection, and largest inventory of coated gloves. We are specialists in Industrial Grade Coated Gloves since 1996. Enhance your employee’s performance and protection, increase gripping, while improving hand ergonomics. Choose from nitrile (NBR), polyurethane, and latex coatings. Glove linings include cotton/polyester blends, texture nylon, hi-visibility yarns, aramid, Kevlar and Dyneema cut resistant fibers. Gloves-Online — Where Industry goes for gloves. Call 877-456-8313

2009 Robotics Industry Directory The only free directory that specializes in robot suppliers, integrators and consultants. Includes a “Who’s Who” listing of Robotic Industries Association Platinum members. A listing in the Robotics Industry Directory is testament to any company’s true place in the industry. Order at Robotics Online Free Resources page. (Bonus: free Motion Control Directory … type *MCA* after your last name on the request form.) Robotic Industries Association 900 Victors Way, P.O. Box 3724 Ann Arbor, MI 48106 734-994-6088 www.robotics.org

www.assemblymag.com July 2009 / ASSE M B LY 43

Advertisement

New high-speed TS series robots

Writing Shelf Provides Extra Workspace

The result of our expertise in fluid-circuit connections and in robotics, our tool exchangers, effectively combine: 䡲 greater compactness and increased time efficiency, 䡲 reliability and performance, 䡲 adjustability to repetitive tasks and resistance to heavy flow rates

Able to carry heavy payloads while maintaining high speed, the TS series of next generation of ultra-fast SCARA robots feature a large work envelope, multiple attachment methods and an IP54 protection rating making it suitable for a variety of industries including: automotive, electrionics, food, life sciences & pharma, machine tending, photovoltaics, plastics & more.

The Writing Shelf pulls out to provide you with extra workspace for writing or sorting paperwork. Featuring heavy-duty ball bearing drawer slides for durability and smooth movement. This item is compatible with our C-Leg Series and RTW Tables and can be stacked with any of our modular workstation drawers. Get organized and increase productivity with a Writing Shelf today.

Stäubli Corporation 201 Parkway West PO Box 189 Duncan, SC 29334 (USA) 800-845-9193 www.staubli.com

Stäubli Corporation 201 Parkway West PO Box 189 Duncan, SC 29334 (USA) 800-845-9193 www.staubli.com

Production Basics 800-318-2770 [email protected] http://shelf.pbasics.com

Stäubli Connectors Toolchanger

Cincinnati Test Systems, Inc. Expands Sealing Connector Offering The Better Cam Indexer The innovative cam tables and rings from Weiss North America allow for maintenance free operation. Weiss offers an industry best four year warranty standard on all indexers. Our tables and rings come filled with oil and sealed for life. High precision with no need for mechanical overload clutches ever! Reliable. Precise. Weiss

Industry’s Best In-Process Monitoring sigPOD PSV is an out of the box, user configurable solution to address a wide variety of standard applications, such as press, torque, dispense, weld, NVH, and more. Our easy to use set-up wizard makes it simple to leverage Sciemetric’s Signature Analysis technology to maximize yield and reduce costs.

Cincinnati Test Systems now offers an expanded line of both air actuated and manually actuated sealing connectors for leak testing, plugging and filling applications. Connectors are designed for smooth, rough and even threaded internal and external diameter connections as well as specialty seal materials and Luer type connections used in medical device products.

Weiss North America, Inc. www.weissna.com 888-WEISSNA (934-7762) Sciemetric 866-900-7054 [email protected] www.sciemetric.com 44 ASSEMBLY / July 2009 www.assemblymag.com

Cincinnati Test Systems, Inc. 5555 Dry Fork Road Cleves, OH 45002 [email protected] www.cincinnati-test.com

Advertisement

Custom Built Machinery Electric Actuators From $170 Mirai Inter-Tech is excited to offer a variety of electric actuators from only US$170! Various speeds, forces, environmental ratings, and feedback options are available as follows: 䡲 Servo control & analog feedback 䡲 Programmable position, speed, accel, etc. 䡲 IP-65 and wide range of operating temperatures 䡲 Clevis-clevis mounting 䡲 High-speed & high-force models Mirai Inter-Tech 905-763-9442 [email protected] www.miraiintertech.com

“Quick Ship” Workbenches When you need it now! IAC Industries’ Work Center Solutions catalog features Dimension 4 and Pro Series workstations, EZE Workmaster workbenches, packaging stations, our Multi-Task System (MTS) utility upper structures for workbenches, and a wide array of productivity accessories all available for shipment within five days of ordering. IAC Industries 714-990-8997 IACindustries.com

Stabilizing the Assembly Industry The 351APS pedestal stand is used with compression riveters in order to provide a hands-free option where stable use of the tool or the use of both hands is required. The stand comes with a foot pedal control attached by an 8 foot hose for added flexibility of operation. Michigan Pneumatic 1-800-521-8104 www.michiganpneumatic.com

Direct Acting Air Press features Integrated Process Control New SCHMIDT® PneumaticPress 320/PressControl 3000 System with integrated sensor technology is well suited for low force applications of up to 360 lbs. System provides real time process control, force and stroke monitoring and 100% process verification. Roller-guided round ram and internal load cell are both protected from side loads. SCHMIDT Technology 800-959-1218 www.schmidtpresses.com

CBM provides Total Automation and Integration Solutions customized to accommodate your production needs, large and small. We specialize in custom automation equipment and custom assembly machines for the pharma, medical device, and food industries, as well as other industries that require a controlled production environment. We will work with you hand in hand throughout the entire project and ensure that you are satisfied at every phase. Let us help you reduce labor, increase throughput, and save money. Call or send us an email and tell us your needs, we are ready to provide a quote on your next project. CBM Inc. 2614 S. Hickory Street Santa Ana, CA 92707 714-424-9250 [email protected] www.cbminc.net

ClinchTech Clinch Joining/Assembly Tooling Aries Engineering Co., Inc/HyperCyl now offers a complete line of both round and rectangular shaped clinch tooling – ClinchTech. It’s unique, patented design improves joint strength while reducing the pressing force required. 3mm- 8mm standard sizes, custom tooling is also available. Aries Engineering Co., Inc. Dundee, MI 48131 Sales@ hypercyl.com

www.assemblymag.com July 2009 / ASSE M B LY 45

Advertisement

Automatic/Robotic Tool Changers

Small Parts Handling & Storage

ATI Industrial Automation is the leading supplier of Automatic/Robotic Tool Changers. Tool Changers provide flexibility to robot applications by allowing the robot to change end-effectors (e.g. grippers, vacuum cup tooling, pneumatic and electric motors, weld guns, etc.) automatically, using a patented fail-safe locking mechanism. ATI also supplies robotic accessories and robot arm tooling, including Multi-axis Force/Torque Sensing Systems, Robotic Deburring Tools, Robotic Collision Sensors, Rotary Joints, and Compliance Devices.

Molded Fiber Glass Tray Company manufactures a wide range of sizes and styles of small reinforced composite boxes for the handling of parts for kitting and assembly operations. Lids are available to protect the contents. These will withstand a heavy load. Visit our website at www.mfgtray.com, or call Customer Service at 1-800-458-6050.

ATI Industrial Automation 1031 Goodworth Drive Apex, NC 27539 919-772-0115 Fax: 919-772-8259 [email protected] www.ati-ia.com

Molded Fiber Glass Tray Co. 6175 U.S. Highway 6 Linesville, PA 16424 814-683-4500 Fax: 814-683-4504

Precision Index Conveyor Northstar Industries Inc. has developed a cost effective solution to precision index applications. The new line of conveyors is easily mounted and features pneumatic operation with positive pallet location. Standard units are available from 6” to 12” wide and lengths from 4 to 10 feet. List prices start at $12,120. Northstar Industries Inc. 25 Heritage Drive Tiffin, OH 44883 419-455-9258 www.tiffinnorthstar.com

Modular Roller Conveyor System

Threaded Inserts for Plastics Tri-Star’s 20-page, full-color catalog details their complete line of Threaded Inserts, Precision Machined Products, Compression Limiters and Knurled Spacers. The company offers technical, application and installation assistance and has the ability to design and manufacture custom inserts for special projects. Visit our website for up-todate offerings, including our growing line of mold-in products. Tri-Star Industries, Inc. Berlin, CT 800-882-8980 www.tristar-inserts.com

The Modular Roller Conveyor System MRC utilizes Adjustable Friction Rollers for accumulation and transfer of pallets or products. The MRC system can transport product or pallets at speeds up to 18 m/min while accommodating pallet loads of 350 kg. Simple diverter devices accommodate automatic transfer of pallets at intersections.

Automation & Modular Components, Inc. 10301 Enterprise Drive Davisburg, MI 48350 248-922-4740 Fax: 248-625-3730 [email protected] www.amcautomation.com

46 ASSEMBLY / July 2009 www.assemblymag.com

ATEQ 5 SERIES With more than 35,000 leak testers currently in operation throughout 32 countries, ATEQ remains by far the largest manufacturer of leak testing instruments for production lines in the world. With the 5 series, ATEQ introduces the fastest, most reliable, versatile, user friendly leak tester range in the market, and by far the most popular ever built. ATEQ CORP. 42000 Koppernick Road Canton, MI 48187 734-451-9449 [email protected] www.ateq.com

Advertisement

ADVERTISE IN ASSEMBLY’S PRODUCT REVIEWS MultiLine — Material Flow Solutions 䡲 䡲 䡲 䡲

Flexible Modular System Lean Manufacturing Solution Increased Productivity Low Cost / Quick ROI

Sovella Inc. 800-437-6772 [email protected] www.sovella.us

New EC Tooling With Tau and Theta Controllers From Stanley! Stanley introduces new value to precision fastening. The new EC line of tooling with the Tau and Theta controller provides full transducer control at value price levels from .5 to 200Nm in all configurations. EC tool packages offer a scalable plant interface while not compromising joint quality or production performance. For More Information Contact Michael Poth at [email protected], visit www.stanleyassembly.com, or phone 440-461-5500

Contact Vito Laudati for details Phone: 610-694-4018 Fax: 248-283-6618 [email protected]

Classified Need Work Benches

?

www.1proline.com In Stock

847-534-1000 LEAN CELL SPECIALISTS ⽧ CUSTOM ASSEMBLY EQUIPMENT ⽧ ⽧ QUALITY CONTROL SYSTEMS ⽧ ⽧ SPECIAL MACHINERY ⽧ ⽧ SPECIAL FIXTURES ⽧ ⽧ PRECISION CNC MACHINING ⽧

www.krygierdesign.com

www.assemblymag.com

For information on Classified Advertising call Vito Laudati: 630-694-4018 www.assemblymag.com July 2009 / ASSE M B LY 47

CASE STUDY

Advertisement

Advertisement

Tool Changers Providing Needed Flexibility

Marson tool salvages 800,000 rivets.

T A

customer of Alcoa Fastening Systems working with all aluminum 3/16” diameter open-end blind rivets reported that the mandrel was breaking 1/2” up the mandrel shaft. This left approximately 1” of the mandrel exposed above the eyelet body flange, resulting in a 30% installation failure rate. Following Alcoa’s Q-C lab inspection process, an on-site inspection was scheduled at the customer’s assembly plant. After several more assemblies were completed with observed failures, visual inspection of the spent mandrels revealed the issue: the jaw bite was less than 1/2” down from the mandrel point, indicating that the riveting tool being used was not fully engaging the mandrel. This was causing the tool jaws to break the mandrel prematurely above the rivet head. Commonly referred to as Mandrel pull through (spiking)…yet all rivet and application dimensions were with in spec. After agreeing to try the Marson MP-3V air-driven riveting tool, the customer completed 4 additional assemblies with no failures whatsoever. Subsequently, the customer has been using the Marson MP-3V installation tool with no reported failures to date. The MP-3V was able to salvage 800,000 rivets, and ultimately, realize a significant time and cost savings to the customer. Alcoa Fastening Systems Ron Chike AFS-IDG Industrial Sales Manager [email protected] Office: 800-826-2884 Visit us at www.AFS-IDG.com

48 ASSEMBLY / July 2009 www.assemblymag.com

o compete in a formidable and uncertain market, many automakers are adopting flexible manufacturing into their strategy to cut costs and increase flexibility and quality. This flexible manufacturing process utilizes robots and tool changers in manufacturing multiple cars on one assembly line. Traditionally, most assembly plants are limited by their ability to produce only one car model. When demand for the model being produced drops, the plant works at less capacity. And when the plant is re-tooled for a new model, much of the costly equipment is scrapped. Flexible manufacturing enables assembly plants to build a different model car automatically by switching endeffector tooling. This approach allows multiple models to be built by one plant, making the plant much more responsive to demand. In addition, a new flexible plant re-fit only costs a fraction of a traditional plant re-fit. Chrysler is one of many companies that have adopted this flexible manufacturing process. As stated in IndustryWeek “We wanted to do changeovers in hours or days versus weeks -- not only to save money but to rapidly gain market share when a product is hot,” said Frank Ewasyshyn, Executive Vice President – Manufacturing, Chrysler. ATI’s engineering staff, the largest of its kind for a robotic tooling company, has created many solutions to resolve the engineering obstacles associated with this type of state-of-the-art manufacturing environment. Visit www.ati-ia.com for more information on ATI’s end-effector products and to see more information on this topic. ATI Industrial Automation 1031 Goodworth Drive Apex, NC 27539 Phone: 919-772-0115 Fax: 919-772-8259 Email: [email protected] Web site: www.ati-ia.com

Advertisement

Screwdriving System Saves Time and Money

UV/VIS Adhesive Ruggedized DC Motor

C

ell phone towers are a nearly ubiquitous feature of every city, town and roadway in America. These towers send and receive signals to and from your cell phone. The towers are equipped with filter boxes that filter the highfrequency range to generate a narrow-band signal for the data stream. The clarity of each filter is adjusted by one or more setscrews, or threaded pins, which are mechanically positioned in each filter chamber to an axial depth. A counter-nut does the exact positioning and mechanically locks the setscrew. When the nut counters the setscrew, it is possible for the adjustment to shift on its own because of a threadbacklash. To avoid this effect and eliminate repeated adjustments, manufacturers of filter boxes use custommade setscrews, which are very expensive and still do not solve this thread-backlash problem. DEPRAG has developed a new screwdriving system specifically for manufacturers of mobile phone technology. This system dramatically reduces cycle time when installing and adjusting the setscrews. It also saves these manufacturers money by enabling them to use standardized hardware instead of custom-made setscrews. The system consists of a screwdriving head that accepts both the setscrew and the nut (see picture). Once both fasteners are supplied to the screwdriving head, the setscrew is driven through the nut into the filter box. Thereafter, the nut is countered, without letting go of the setscrew, and its position is therefore positively locked. Lori Logan Marketing Manager DEPRAG Inc. 640 Hembry Street Lewisville, TX 75057 (800) 433-7724 Toll-Free (972) 221-8731 Phone (972) 221-8163 Fax [email protected] www.depragusa.com

A

manufacturer involved in the appliance/power tool markets needed a way to ruggedize their line of DC motors to make them more robust, reduce the number of field failures and replacement units, and increase the consumer’s confidence in the quality of the tools they were using. The DC motors utilized a rotating commutator that spun inside magnets at high speed. If the copper wire were to come loose from the armature mount on the commutator, this would change the center of gravity of the spinning shaft, causing a wobble, which would degrade the efficiency of the motor and damage it. DYMAX recommended Multi-Cure 6-602-GEL adhesive because of its multiple-cure mechanism, which enabled it to cure with UV/VIS light, or heat, or in combination with an activator. This allowed the vendor to unitize the armature wires then thermal bake any resin deep in the commutator windings that did not see light. They also used a DYMAX high-intensity light source that emitted a broad spectrum of UV/VIS light at intensities up to 2,500 mW/cm2, which was necessary for the depth-ofcure and tack-free surfaces dictated by the application. The process involved applying 6-602-GEL (with a nominal viscosity of 25,000 cP) with an air/pressure dispensing system and needle tip applicator while the rotor was spinning, so the adhesive spread out evenly over the wires, and then curing it with a UV/VIS lightguide for 5-10 seconds. DYMAX 6-602-GEL cured in seconds and provided exceptional adhesion to the substrates as well as impact and shock resistance. DYMAX® Corporation 318 Industrial Lane Torrington, CT 06790 Toll Free: 1-877-DYMAX-UV (877-396-2988) [email protected] www.dymax.com www.assemblymag.com July 2009 / ASSE M B LY 49

CASE STUDY

Advertisement

CASE STUDY

Advertisement

Rotary Dial System

Advertisement

EFD Dispensers Cut Assembly Time 83%

S A

rotary dial system built recently by EDGEWATER AUTOMATION (St. Joseph, MI) was purchased by a manufacturer who needed a machine to assemble an automotive switch with seven variants. Previously, they were using three individual robots, each robot taking 43 seconds to complete a switch. The manufacturer turned to EDGEWATER AUTOMATION to help solve this problem. EDGEWATER came up with the eight station Rotary Indexing Dial machine for programmable, point to point soldering of electrical switches to circuit boards. This machine not only saved the customer time (the dial index machine is twice as fast as the three robots combined) and money, but also saved them half their floor space. Because of the number of current and future model variants to be assembled on this machine, a high degree of flexibility and programmability was required. The end user states that their expectations were exceeded with the quality and the low PPM reject rate. And at the end of the day, the customer is pleased with minimal maintenance requirements. This machine is simple, cost effective, precise, reliable and durable. For more information please contact Edgewater Automation at 269-983-1300 or visit www. edgewaterautomation.com Edgewater automation 481 Renaissance Drive St. Joseph, MI 49085 www.edgewaterautomation.com 269 983 1300 [email protected]

50 ASSEMBLY / July 2009 www.assemblymag.com

witching from toothpicks to EFD dispensers helped an electronics manufacturer cut use of an expensive silver-filled epoxy by 50% and reduced assembly time from 30 minutes to 5 minutes per part. The company builds membrane switches used in touch-pad applications. Because soldering’s intense localized heat could damage the flexible circuits inside the switches, the company uses silver-filled conductive epoxy to attach components. Operators used toothpicks to spread the expensive adhesive on small contacts on the flex circuits, but the company president knew there had to be a better way. Seeking a more accurate and efficient application method, he contacted EFD for information on their automatic dispensing equipment, which uses a precisely timed air pulse to apply epoxies, adhesives, solder pastes and other assembly fluids in accurate, consistent amounts. With time-pressure dispensers, shot size is determined by a combination of air pressure, dispense time, and tip size. With setup completed, tapping the foot pedal produces an identical deposit every time. The company now has two EFD dispensers in daily operation. The ability to apply epoxy quickly and accurately and eliminate waste has lowered their adhesive costs by 50% and dramatically reduced assembly time. “Besides being expensive,” the president says, “the epoxy we use has a very short pot life, so we have to get it on the contacts quickly. That’s where the dispensers really shine -- we went from 30 minutes to 5 minutes per assembly, for an 83% increase in productivity.”

EFD, Inc. 40 Catamore Boulevard East Providence, RI 02914 800.556.3484 401.431.7000 www.efd-inc.com/pr/asm-0709 [email protected]

Advertisement

Advertisement

Ellsworth Develops “Cold Solder” Process

A C

onnecting wires to flexible circuits can be a challenge. The high temperatures used in conventional solder methods can damage substrate materials. Solder alternatives, silver-filled conductive epoxies, cure in hours versus the much shorter assembly times provided by solder techniques. Ellsworth Adhesives recently worked with a customer bonding wires to silver coated PET. The customer needed a fast assembly method that would not damage flexible circuit materials, but would provide high-durability connections and maximum conductivity. The solution involved using a UV cure urethane in combination with a silver-filled epoxy. Step one of the process was to connect the wire to the silver circuit and apply the silver-filled epoxy over the connection. Step two was to dispense a small drop of UV encapsulant over the epoxy/wire/substrate connection. While holding the connection together, the assembly was then exposed to UV light. The rapid UV cure fixtured the assembly together holding the wire and flex circuit together with the filled epoxy connection. With the connection in place, the epoxy was then cured using a prescribed cure schedule. Ellsworth was able to provide the epoxy in two forms, premixed and frozen in syringes and in two component flexible packaging for transfer to one component syringes. Ellsworth Adhesives W129N10825 Washington Dr. Germantown, WI 53022 (Ph) 800-888-0698 (Fax) 262-253-8619 [email protected] www.ellsworth.com

prominent automotive parts manufacturer that powder coats parts for a hard, tougher finish needed better gloves that provided day-long comfort, good grip with high dexterity; eliminated deposit of body oils and lint on parts; and offer cost savings. The manufacturer tried various gloves for this new production line but workers found these gloves uncomfortable to wear for long-shift work; increased hand fatigue and perspiration; or left lint on parts. Other less expensive gloves also wore out quickly since workers had to load 25,000 parts per day onto the production conveyor hangers. The manufacturer turned to GO Gloves™ (GlovesOnline, Inc.) for a solution since they were experienced glove specialists and handled a broad range of gloves for industrial applications. Once GO Gloves identified the production requirements and problems together with worker’s concerns, they offered 3 coated glove options based on performance, comfort, and price. After weeks of testing the finished parts and reviewing worker evaluations, the manufacturer selected the AllDay® Micro-Dot Gloves since this model addressed each production problem and increased worker acceptance. The solutions that the Micro-Dot Gloves provided were thinness, close fit, dust and lint free, great tactile and grip properties, breathablity, and worker comfort. Besides being very cost effective, the manufacturer only had to stock 2 sizes; one universal stretch size and one extra small size for women with small hands since more sizes would have been required with conventional coated gloves. GO Gloves Gloves-Online, Inc. 261 Towerview Court Cary. NC 27513 919-468-4244 Fax 919-468-4245 www.industrial.gloves-online.com [email protected] www.assemblymag.com July 2009 / ASSE M B LY 51

CASE STUDY

Micro-Dot Gloves Resolve Parts Handling Problems

CASE STUDY

Advertisement

Advertisement

Multiple Measurements One LaserGauge®

Lista Workstations Aid Digital Monitoring Products

D

igital Monitoring Products is a leader in network solutions for fast, cost-effective, centralized security monitoring in applications of every size. The company was at the forefront of digital communications in the security industry, and today continues to set standards with its networked intrusion, fire and access control products. DMP’s manual assembly is used to handle insertion of odd-form components that cannot be machine- inserted. For over five years, Arlink® 8000 workstations from Lista International Corp. served DMP well as the central element in the company’s manual product assembly. Lista is a world leader in modular storage and workspace systems. Problems arose for David Peebles, DMP’s VP of Manufacturing on assembly lines. Peebles needed to incorporate a progressive assembly system to address this, optimize efficiencies and prepare the assembly department for growth and expansion. Fortunately, Arlink 8000 workstations are accommodating. The Arlink 8000 modular workstations are designed to accommodate changing or future needs. Configured in a variety of heights and lengths, they feature a unique “starter and adder” system with optional back-to-back configurations that enables unlimited layouts to adapt to any space or support any process requirements. The workstation’s Definite Positioning System® makes relocating or adjusting worksurfaces, storage, shelving, lights, power beams, footrests, etc. fast, easy and safe. “Lista’s Arlink 8000 is a great value – an easy-toassemble solution that’s high quality as well as costeffective. Lista’s salespeople and design team have provided excellent support. We’re looking at adding three additional new lines, and Lista workstations are top of mind.” Lista International Corporation 106 Lowland Street, Holliston, MA 01746 TEL 1-800-722-3020 FAX 508-626-0353 EMAIL [email protected]. Visit Lista’s web site at www.listaintl.com.

52 ASSEMBLY / July 2009 www.assemblymag.com

A

n automotive manufacturer was using the LaserGauge® system to measure gap and flush on exterior fits as a part of its final-line inspections. A potential out-of-spec condition that involved a seal protruding out of a closure gap was frequently noted by inspectors. The specs allowed the seal to protrude to a specified height relative to the panels, but the inspectors had no reliable means of measuring the seal. Since the profile of the seal and the surfaces of the adjacent panels could all be seen in the scans captured by the LaserGauge®, the inspectors contacted Origin to find out if the height of the seal could be measured at the same time as the gap and flush. Because LaserGauge ® measurements are made in software, it was a simple matter of modifying the algorithm to identify the seal’s surface and to determine the maximum height of the seal relative to the adjacent panels. Using sample scans collected by the inspectors, the algorithm was modified and provided to the plant for immediate implementation. From that point forward, the inspectors were able to base their findings on accurate and repeatable measurements. One LaserGauge® system can be used to perform a range of inspections: 䡲 Corner Radius and Flange Length on sheet metal parts 䡲 Gap and Flush on BIW and all color surfaces 䡲 Height of seal between assembled panels 䡲 Angle and Eruptions on spot welds 䡲 Undercut, Concavity and Convexity on welds

Origin Technologies Corporation 256-461-1313 www.origintech.com

Advertisement

Advertisement

CASE STUDY

Steering Knuckle Bushing Press APPLICATION: Assembly of bushing into the right and left angular steering knuckles used in transportation industry. PROBLEM: A new design steering knuckle using conventional, non-controlled hydraulics assembly presses was creating 10% to 12% rejections during the assembly process. A total tolerance of +-0.5mm is required on the position of the bushing relative to a phantom datum point on the casting. This tolerance or less must be held over millions of parts, despite the fact the casting tolerance, with phantom tolerance, was three times the finished assembly tolerance. Using closed-loop feedback from an external position transducer built into the fixture/tooling, the sensor communicates to an Electrical Mechanical Assembly Press (EMAP) which measures the assembly as it is being made and compensates in real time, for variations in the individual parts. The bushing position is now held to better than +- 0.1mm. SUMMARY: The closed-loop EMAP system functions as both a controlled Electric assembly press and gauge. The system has on board force monitoring and external sensing capability, standard. This allows the systems to measure, calculate, and offset for deflection and variance in part tolerance, while it is making the part to tolerance. Micron wear of tooling and fixture, over time, are detected and compensated as part of finished part tolerance to provide greater part quality and equipment up time. Assembly rejects on the steering knuckle bushing press are now less than .001%. Systems also includes force vs. position signature visualization HMI with alarms to ensure the press fit, and stores information for recall and later analysis.

S

ankyo America, Inc. was chosen by major machine builder to provide high speed indexer with accuracies that needed to be very tight for injection molded parts on US auto maker door fittings. The tolerances needed to be held at +/- 0.002” at a 30” radius. The machine builder, Pro-Systems, located in Indiana has had a longstanding relationship with their customer and knew that they could not afford to go with any other cam index company. The repeatability required of this particular application could not be negotiated. The Alpha series indexer provided by Sankyo America, Inc. was ran and tested at +/- 0.0016 at the 30” radius. Sankyo America, Inc. “The Global Standard in Cam Indexing” 937.498.4901 www.sankyoamerica.com 10655 State Route 47 PO Box 4338 Sidney, Ohio 45365 [email protected]

Promess Inc. 11429 Grand River Road Brighton, MI 48116 810-229-9334 [email protected] www.promessinc.com www.assemblymag.com July 2009 / ASSE M B LY 53

CASE STUDY

Advertisement

Advertisement

ServoPress Station

Effective Heat Management with Casting Materials

Assembles and Marks Transmission Component

D

uring operation many automotive electronic devices produce heat. Such heat must be effectively dissipated to prevent the device from overheating. Excellent thermo conductivity can be achieved already during manufacture by using especially composed casting resins with the appropriate heat dissipating properties. Problem: Overheating Managing the heat generated by automotive electronic components presents one of the major challenges when choosing production materials. If the heat produced by power losses is not properly dissipated, a device is likely to overheat. For example, a simple mechanical installation creates an air gap, which insulates the part that is generating the heat. As a result, heat cannot be properly dissipated. Solution: Flush Contact with the Cooling Ambient Air Successful cooling can only be guaranteed if the heatconducting elements and the cooling ambient air show optimum surface contact. In other words: flush thermal contact with reliable electrical insulation. In the electronics industry, an increasingly popular trend is to use heatconducting resins. If care is taken to dispense the casting material bubble-free a perfect surface contact is established simultaneously. Therefore, with the correct resin and dispensing system, managing heat conductivity becomes a simple, inexpensive and extremely flexible manufacturing step. Scheugenpflug systems have proven their abilities during their use in production over many years. Customer Benefits: This method may well be the most profitable in the industry, because it is saving costs in two major areas of manufacturing. First, a single casting material can handle substrates of different shapes. Second, casting resins are less expensive than other heat-conducting connectors.

Scheugenpflug, Inc. 2125 Barrett Park Drive NW, Suite 104 Kennesaw, Georgia 30144, USA 770 218 0835 [email protected] www.scheugenpflug-usa.com 54 ASSEMBLY / July 2009 www.assemblymag.com

SCHMIDT® ServoPress Model 460 and Transmission Component Assembly

A

well-known manufacturer of automotive products worked with SCHMIDT® Technology, a leading manufacturer of precision assembly presses, to develop a more efficient and cost-effective way to assemble a truck transmission component. The assembly process consists of pressing a countershaft with integral helical gear onto a helical gear. Once assembled, alignment between the lower and upper gear must be within +/- 0.006” with a Cpk of 1.67. Previously, the manufacturer used a hydraulic press to perform the pressing operation. Although the operation utilized keyways in the tooling, a secondary gauging/ testing operation was necessary to verify gear alignment. Another secondary operation painted a transmission timing mark on each gear. To significantly improve these production operations, SCHMIDT Technology designed and built a completely integrated assembly station featuring the SCHMIDT® ServoPress Model 460 (maximum force of 33,000 lbs.) and PressControl 4000. The PressControl 4000 provides fully integrated monitoring for quality and is capable of interfacing with and controlling up to six ServoPresses or other CNC-operated axes. Once initiated, the ServoPress controls the ram until it lightly contacts the part, realigns the parts if necessary, and presses them together. PressControl 4000 software verifies the interference fit while statistically tracking the results. The PressControl 4000 then activates a painting device to mark one gear and a dot peen marker to permanently mark the other gear. Sensors verify part presence and tooling position. And finally, the SCHMIDT® ServoPress System performs and controls all operations during one press cycle while simultaneously monitoring for quality. SCHMIDT Technology Corporation Cranberry Corporate Center 280 Executive Drive Cranberry Twp., PA 16066-6415 724-772-4600 • Fax 724-772-4688

Advertisement

Advertisement

T

ransfer Tool Products started working with SCHUNK, a world leader in Automation, Workholding and Toolholding Technology, to reduce the cycle time within the manufacturing process of stamped air bag components. Utilizing SCHUNK’s HSB gantry axis along with 6 assemblies composed of LM linear units, SRU rotary units and PZN-plus grippers, Transfer Tool Products was able to achieve a 500 millisecond cycle time. This cycle time reduction allowed Transfer Tool Products to reduce the manufacturing cost of this stamped component significantly. The customer states that only SCHUNK products made it possible to get the stamped air bag component through all seven stations within 3.5 seconds and also get it inspected with a vision system throughout the manufacturing process. Transfer Tool Products has tuned the servo motor driving the SCHUNK HSB unit achieving a speed of 35 feet per second. With this machine having millions of cycles without failures, the high speed application can produce over 7000 parts an hour. Overcoming the limitations of other transfer presses, SCHUNK has proven to be the perfect choice.

SCHUNK Inc. 211 Kitty Hawk Drive Morrisville, NC 27560 Phone: 919-572-2705 Toll Free: 800-772-4865 Fax: 919-572-2818 E-mail: [email protected] www.schunk.com

C

hallenge: A major Japanese automotive component supplier required highly precise, advanced techniques to test automotive oxygen sensors, an integral part of automotive emissions systems. The nature of the sensors makes them extremely difficult to test, as the characteristics of the device change when power is applied to them. In addition, production rates could not be slowed, so the testing process would have to be as fast as possible. Solution: Sciemetric’s Model 1508 hardware was loaded with sigPOD™ PSV software, which enabled synchronous testing of 4 units to allow greater throughput at the scale necessary on this major manufacturer’s automated production line. The sigPOD™ PSV software was configured using a simple setup wizard to perform an automated end of line audit test on the standard automotive oxygen sensors. This included setting sampling rates, precise triggers, waveform calculations and signature based feature checks to execute the most precise quality analysis available. The results of each sensor test were archived to a qualityworX™ database where a simultaneous review of thousands of waveforms is performed and stored for future use. Achievement: Precise, fast, and repeatable results without sacrificing throughput or quality integrity. Information captured by the qualityworX™ database can be used to determine production limits, provide complete serialized traceability, deliver evidence of quality conformance and provide valuable insight into production processes. Features & Benefits: 䡲 serialized traceability 䡲 waveform calculator 䡲 stand alone capability 䡲 discrete logic I/O 䡲 dynamic advance 䡲 ethernet IP capable feature checks 䡲 available FFT analysis 䡲 full waveform analysis Sciemetric instruments [email protected] www.sciemetric.com 1-866-900-7054 www.assemblymag.com July 2009 / ASSE M B LY 55

CASE STUDY

Increased Throughput & Precision Quality Assurance for Automated Production Lines

Advertisement

CASE STUDY

Advertisement

Thinking Outside the Box

S

ealant Equipment & Engineering developed the Multi-Function Gun (MFG) to improve the dispensing quality and application speed of 1-component heat cure sealers used in automotive assembly plants and tier-1 suppliers. Prior to the introduction of MFG applicators engineers had to select one type of bead profile (spray, stream or ribbon) per dispensing robot or have multiple valves on one robot to perform multiple bead profiles, each with a different tip. Having multiple valves and hoses on a dispensing robot is cumbersome, costly and difficult to maneuver inside a vehicle. With the support of automotive companies and robot integrators worldwide Sealant Equipment created 5 different models of the 2600-022 series Multi-Function Gun to comply with various customer specifications. The plain basic model has evolved into a 3-Tip applicator, a 3-Tip with material re-circulation and a 5-Tip model with various accessories. The 3-Tip Multi-Function Gun uses three (3) KISS Valves with individually selectable dispense tips. The 5-Tip Multi-Function Gun uses five (5) KISS Valves with individually selected dispense tips to dispense the right bead profile. KISS No-Drip® high-pressure dispense valves are ideal for the automated application of pumpable materials. The needle, seat and flow-through design technology enables the KISS valve to perform longer with high volume applications, frequent on-off cycles per part and abrasive materials. KISS valves incorporate a carbide hardened needle/ ball and carbide seat with an abrasion resistant seal to further increase its life cycle and reduce down time. For more information on automotive applications and capabilities visit http://www.sealantequipment.com/ automotive.htm To view automotive application videos visit http:// www.sealantequipment.com/videos.htm#AutoIndustry

Sealant Equipment & Engineering, Inc. 45677 Helm St., Plymouth, MI 48170 ph: (734) 459-8600 [email protected] www.SealantEquipment.com 56 ASSEMBLY / July 2009 www.assemblymag.com

M

anaging down time in high production operations is a continuing challenge. Nowhere is this more important than in the automotive sector. Often it requires investigating and implementing different methods to accomplish the same task. In this case the task resulted in replacing a competitor’s marking laser with micro-percussion technology. APPLICATION: Marking aluminum cylinder heads with 18 human readable characters and a Data Matrix code faster than the laser marking system. PROBLEM: The competitor’s laser was unreliable with 20 hours of downtime over an 8-month period and it proved difficult to troubleshoot and support. SOLUTION: Using the high speed Technifor XF510Cp the complete marking was accomplished in less time than the laser. Only a fraction of the marking speed’s capacity was needed in this application. BENEFITS SUMMARY: The pricing was 1/5 the cost of the laser, cycle times reduced, and reliability improved. The solution was implemented in less than one day. Technifor offers a full product range of micropercussion, scribe, and laser marking technologies as well as free in plant analysis and sample processing. Customers have free access to 24hr service, repairs may be turned around in one day and spare parts are in stock.

Technifor, Inc 704-525-5230 [email protected] www.technifor.com

Advertisement

Belting out Belts

Automotive Manufacturer Improves Component Assembly with TURCK Weld Nut Sensor

A

n off the shelf ball screw actuator and controller has made it possible for one operator to produce six times as many drive belts per shift. In the past, when operators manually indexed a knife to cut the belts, they could produce about 100 per hour. Stock Drive Products, New Hyde Park, New York, the company that produces the belts, had the idea of automating this difficult and expensive job. A sister division, Techno, Inc. also based in New Hyde Park, created a design that uses standard components to completely automate the job. The new belt slicing machine produces 300 belts per hour with minimal manual intervention, making it possible for a single operator to run two of the new machines simultaneously. Quality is also improved by the consistency of the automated slicing operation. “The new automated machine substantially reduces the cost of producing timing belts while demonstrating how small, low-cost automation projects can provide a big payoff,” said Bob Gaulrapp, Manufacturing Manager of Stock Drive Products. The result, according to Perry Pierides, Manager of the Belt Department, is a dramatic performance improvement. “The operator simply puts the sleeve on the machine and enters the program on the controller for the width of belt that they want to produce,” Peirides said. The machine paid for itself in a matter of months and continues to provide major manufacturing cost savings. Meanwhile, the belt slitting job has gone from one of the least to one of the most desirable in the shop.” Techno Linear Motion Systems 2101 Jericho Turnpike New Hyde Park, NY 11040 (516) 328-3970 Fax (516) 358-2576 Contact: Joe Griffin, Linear Motion Products Sales Manager [email protected] www.technoautomation.com

T

o determine if a nut on a bracket was in the right spot during component assembly, a large automotive manufacturer used to manually “eyeball” or use expensive cameras to confirm the nut was properly placed. The correct placement of the nut is essential to ensuring that the design of the vehicle is unhindered and eliminates the costly alternative—scrapping the entire assembly up to that point in production. The manufacturer now uses TURCK’s magneticinductive weld nut sensor to provide accurate, efficient detection—at a more cost-effective price than alternative solutions. In this application, the nuts are attached to a bracket and detected by the TURCK sensor prior to welding. After the nuts are detected, the bracket is welded to the floor pan of the vehicle, where other assembly components are then fastened to the nut. During set up, the nut and bracket assembly is fitted over TURCK’s weld nut sensor. This sensor has been programmed—using a simple teach function— to differentiate between the sheet metal and the nut, so no additional programming is needed for proper functioning. The weld nut sensor saves configuration time and company money by providing a simple, reliable and affordable tool to improve assembly processes on the plant floor. TURCK 1-800-544-7769 www.turck.us [email protected]

www.assemblymag.com July 2009 / ASSE M B LY 57

CASE STUDY

Advertisement

CASE STUDY

Advertisement

Conductix-Wampfler Assembly System

Advertisement

WEISS North America

C

I

n Niepolomice, Poland, MAN Nutzfahrzeuge Group built the most modern truck plant in Europe, which, by 2010, will assemble 15,000 trucks annually in a continuous flow. A critical part of the assembly line is an integrated compressed air, electric power, and tool transport system designed by Conductix-Wampfler. “With MAN, we developed a complex roof structure to support and power all assembly tools along their respective line segments”, explains project manager Daniel Schlösser. The system gives the assembly operator great flexibility all along the line. A key component is the extruded aluminum W5-traxX “media rail.” This unique rail has a compressed air pipe formed within the extrusion. Compressed air, electric power, and data lines are carried from the rail to the assembler via an integrated cable chain system. The outside of the rail accommodates moving transports for assembly tools. The system can be expanded to include a contactless system to provide the exact position of the carts and automatic data collection. “The high load capacity, rigidity, and operational flexibility of the system allow us to use crane systems, handling technology, lighting, and compressed air supply systems wherever needed. The system can be adapted to changing requirements. Conductix-Wampfler planned and coordinated the whole project, assembled the steel framework, lamp controls, and stationary compressed air supply,” says MAN plant manager Marc Sielemann. Conductix-Wampfler Mike Bjornstad, Handling Products Market Manager 1-800-521-4888 (1-402-952-9327) [email protected]

58 ASSEMBLY / July 2009 www.assemblymag.com

enterline (Windsor) Limited Machinery Division is a full service integrator/machine builder of tube processing, metalworking, and welding systems. Centerline had a need for a heavy duty rotary positioner for their automotive body and frame robotic weld cells. The need stemmed from increasingly heavier loads than their current solution could accommodate. Weiss North America, Inc designed and manufactured the CR series of barrel cam index tables for just such heavy, dynamic loads. The Weiss solution fit Centerline’s needs due to the ability to index their loads quickly, accurately, and with extremely fast E- Stop times. The CR table was also advantageous due to its compact design, zero backlash, full programmability, and maintenance free operation for life. The technology behind the Weiss CR tables is the continuous engagement of multiple cam followers at all times. Traditional tables will have one or two followers engaged in the cam, while the CR has a minimum of five and up to eight depending on the table size. This gives the CR an enormous mechanical advantage over traditional cam indexers and gear driven positioners. Centerline has now integrated the Weiss solution into their REV-TEC™ product line to provide customers with the optimum in rotary table solutions. They currently offer five table sizes for payloads ranging from 500-9000 kg. Their low profile, robust designs are offered with secondary trunions and many practical options that enable the REVTEC™ tables to satisfy virtually any automation need. The principal benefits to this product line include: zero backlash, fast index and E-Stop times, extremely smooth and accurate operation, infinite positioning capabilities, maintenance free operation and Weiss’ 5 year limited warranty support. Details of the unique REV-TEC™ product line can be found at www.cntrline.com. Weiss North America, Inc. 3860 Ben Hur Ave Willoughby, OH 44094 www.weissna.com 888-WEISSNA (934-7762)

Subscribe or Renew Online Today! Just go to www.assemblymag.com and click on

SUBSCRIBE

Products Modules Grip and Rotate New DGP404 parallel grip and rotate modules with T-slot guides can be used in high-load

Safety Laser Covers Complex Areas SZ Series Type 3 safety laser scanners allow users to configure protection areas anywhere, even in complex-shaped zones and dangerous areas. The scanners’ compact body and light weight help facilitate installation and save space without compromising quality or detection range. A built-in muting function lets the scanner ignore certain areas of the protection zone to allow for passage of targets. Unlike light curtain muting, scanner muting results in a much tighter protection zone, minimizing dead zones around passing targets. Keyence Corp. www.keyence.com/sz 888-539-3623

SCARA Line Features Curved Arms The G3 line of compact SCARA robots provides high speeds and precision for use in a wide range of assembly applications. The robots are available with reaches of 250, 300 and 350 millimeters. Class 10 cleanroom and ESD compliant configurations are also available. G3 robots include a curved-arm option to maximize work envelope usage. By employing a curved arm, a G3 with a 350-millimeter is able to match the motion range of a larger 400-millimeter SCARA robot, without occupying a larger footprint. EPSON Robots www.robots.epson.com 562-290-5910

automation applications that require parts to be sorted and rotated 90 or 180 degrees. The grippers are compact, and the T-slot guides help absorb large forces and moments. The modules are available in six different configurations, including those that perform both inside and outside gripping. Techno-Sommer Automatic www.techno-sommer.com 800-819-3366

Valve Provides Micrometer Control The Model 455 pneumatically operated, twoway pinch valve features micrometer control over the flow rate, ensuring that materials are dispensed repeatedly and accurately. The

Bulk Systems Dispense Sealants, Adhesives New line of small ram bulk supply systems can be used to transfer sealants and adhesives from 20-, 30- and 60-liter containers. The systems are available with Check-Mate pumps, which feature a quick-disconnect coupler for easy maintenance, cartridge throat packings for easy servicing, and optional MaxLife coatings on all rods and cylinders to increase the life of the pump. Graco Inc. www.graco.com 877-844-7226

New Linear Bushings Available valve features proprietary over-stroke adjustment, positive shutoff and disposable inert wetted parts, enabling users to obtain millions of cycles from a single piece of tubing. The valves can be easily integrated into an automated assembly line and can be fitted with a number of different dispense tips and spray nozzles. Tridak LLC www.tridak.com 860-626-6700 60 ASSEMBLY / July 2009 www.assemblymag.com

New pillow-block-type linear bushings are available with clamp levers or MX-type self lubrication. The bushings with clamp levers are available in a range of sizes and in single or double versions. The self-lubricating bushings offer up to 2.5 times the durability of non-greased bushings. Misumi USA www.misumiusa.com 800-681-7475

Tool Measures Torque, Angle The CTA2 digital torque and angle wrench combines two tools in one. Operators can enter snug torque and angle data either through

needed. A three-point locking handle securely latches doors when closed. IAC Industries www.iacindustries.com 714-990-8997

Safety Systems Enable Leaner Cells the tool’s keypad or via PC software. Upon reaching the desired snug torque, the display automatically changes from torque to angle mode. When approaching the set angle an intermittent buzzer sounds, and when target angle is achieved a blue lamp lights and a steady buzzer sounds. Tohnichi America Corp. www.tohnichi.com 847-272-8480

The SafeMove system is a software- and electronics-based safety system that is directly integrated into a robot’s controller. It provides safety rated supervision of robot motion, enabling leaner robot cells and more collaborative applications where robots and operators can work more closely together. The system offers a host of leading-edge safety functions and reduces the need for traditional safety equipment, such as

especially beneficial in applications that are sensitive to heat. The system includes a unique adjustment feature that provides user control of light intensity to assist in process validation and control. DYMAX Corp. www.dymax.com 877-396-2988

Spin Coat with Ease Vacuum Ejectors Provide Reliability

The SCS 6800 spin coater makes it easy to accurately apply liquid coating materials such as photoresists, polyimides, metal-organics, dopants, silica films and most organic and aqueous solutions. The system’s proprietary circuitry provides precise control of spin

SEAC-RP model vacuum ejectors are configured specifically for use with vacuum spiders and feeders, like those used to manipulate metal sheets in pressing applications. The ejectors

light curtains, safety relays, mechanical stops, mechanical position switches and protective barriers. ABB Robotics www.abb.com/robotics ensure reliable decentralized vacuum generation and use a minimum of compressed air. They feature extremely short gripping and blow off times, thereby facilitating short cycle times in an automated setting. Schmalz Inc. www.vacuworld.com/us 919-713-0880

Gantry Stage is Compact, Precise Compact, low-cost, two-axis linear stepper motor gantries offer low force, high speed, high repeatability, zero backlash and long system life. The systems are capable of very precise position, velocity and acceleration control when integrated with a microstepping drive and indexer. They can

speed, and acceleration and deceleration rates. It is controlled via an easy-to-use three-button keypad and an LCD display on the front panel. Programmable and nonprogrammable units are available. Specialty Coating Systems www.scscoatings.com 800-356-8260

Workbenches Available with More Options

Conveyor Drive Is Compact, Easy to Use

The Workmaster storage cabinet line now includes seven new pedestal configurations providing wide, large-capacity drawers in combination with split-door cabinet compartments. The cabinet pedestals can be used with a variety of worksurface types, including laminates, maple butcher block and stainless steel. The cabinets offer up to 12 cubic feet of storage that can be divided up as

The new iDrive conveyor drive integrates the motor, gearbox and motor controller in a single, space-saving package. The drive, which is available on the 2200 series of conveyors, is be used in a wide range of applications, including laser marking, inspection systems, pick and place systems, assembly, rapid prototyping, wire bonding and fiber optics. H2W Technologies Inc. www.h2wtech.com 888-702-0540

Lamp Provides High Output, Low Cost The BlueWave 75 is a high-power spot lamp that provides a combination of low operating cost with high-intensity output to accommodate a wide variety of bonding applications. The lamp transmits less energy onto substrates, resulting in cooler cures, a feature

a variable speed system that is also reversible for maximum application flexibility. Control switches are easy-to-use, conveniently located and protected by a high-impact case. Dorner Mfg. Corp. www.dorner.com 800-397-8664

www.assemblymag.com July 2009 / ASSE M B LY 61

An Industry-focused market research company

Making the complex clear.

“Clear Seas Research really helped me to clarify my business objectives, assisted me in making better, smarter decisions and streamlined the flow of how my business runs. Thanks to them I have a better relationship with my customers.”

How Can Clear Seas Research Help Your Business?

JOHN E. THOMAS

Clear Seas Research 248.786.1659 [email protected] www.clearseasresearch.com

Advertisers Index Alcoa Fastening Systems................................. 27

ProLine ....................................................................4

AMSP All Metric Small Parts .......................... 40

Promess ............................................................. IFC

ATI Industrial Automation ....................................9

Quality Bearings & Components .................... 37

Assembly Technology Expo 2009.....................7

Saejong Industries ............................................. 40

CDS Corp. .......................................................... 29

Sankyo .................................................................. 14

Clear Seas Research ........................................ 62

Schatz USA Inc. ................................................. 41

Conductix-Wampfler.......................................... 37

Scheugenpflug ................................................... 36

DEPRAG Inc. ....................................................IBC

Schleuniger Inc. .....................................................8

Dymax ................................................................... 31

Schmidt Technology .......................................... 17

Edgewater Automation ..................................... 13

Schunk Inc. .......................................................... 22

EFD ..........................................................................1

Sciemetric .....................................................10, 11

Ellsworth Adhesives ...................................30, 33

Sealant Equipment & Engineering ................. 35

Gloves Online ..................................................... 41

Technifor ............................................................... 33

Hernon Manufacturing ...................................... 28

Techno .................................................................. 23

I & J Fisnar Inc. ...................................................BC

Techno Sommer ................................................. 30

Lista International Corp. ......................................5

Turck .........................................................................3

Origin Technologies........................................... 32

Visumatic Industrial Products Inc. .................. 16

Pfeiffer Vacuum................................................... 12

Weiss North America ........................................ 35

This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.

®

1050 IL Route 83, Suite 200 Bensenville, IL 60106-1096 Phone 248-362-3700 Fax: 630-227-0204

BUSINESS & SALES STAFF TOM ESPOSITO Publisher [email protected] 610-436-4220 ext. 8530

REGIONAL MARKETING MANAGERS BARBARA GRIM BILL DEYOE

LIST RENTAL - POSTAL ROBERT LISKA List Manager 800-223-2194 [email protected] LIST RENTAL - EMAIL SHAWN KINGSTON Account Manager 800-409-4443 [email protected]

ARLEN LUO Overseas Representative NEWSTEEL Media Beijing, China 0086-10-8857-9899 Fax: 0086-10-8216-0061 email: [email protected]

1288 Centerton Rd. Pittsgrove, NJ 08318 856-358-4800 Fax: 856-358-0900 [email protected]

109 Willow Springs Trail Mt. Holly, NC 28120 704-822-6434 Fax: 704-822-6834 [email protected]

INSIDE SALES MANAGER VITO LAUDATI

TINA VULGARIS

CHRIS WILSON

AUDIENCE DEVELOPMENT

2401 W. Big Beaver Rd. Christine A. Baloga — CORPORATE AUDIENCE Suite 700 DEVELOPMENT DIRECTOR Troy MI 48084 Christopher Sheehy – AUDIENCE DEVELOPMENT MANAGER 248-244-8264 direct Katie Jabour – MULTIMEDIA MANAGER 248-283-6528 fax Catherine M. Ronan – CORPORATE AUDIENCE AUDIT [email protected] MANAGER

1050 IL Route 83, Suite 200 Bensenville, IL 60106-1096 630-694-4392 Fax: 630-227-0204 [email protected]

[email protected] 630-694-4018 Fax: 248-283-6618

For subscription information or service, please contact Customer Service at: Tel. (847) 763-9534 or Fax (847) 763-9538 or e-mail [email protected] www.assemblymag.com ASSEMBLY Volume 52, Issue 7 (ISSN 1050-8171) is published 13 times annually, monthly, plus extra issue in July, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $104.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $137.00.00 USD (includes GST & postage); all other countries: $154.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2009, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: ASSEMBLY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Bleuchip International, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to ASSEMBLY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

www.assemblymag.com July 2009 / ASSE M B LY 63

Leading Lean Jamie Flinchbaugh Partner The Lean Learning Center Novi, MI

Solve the Right Problem

E

veryone solves problems every day, at home and at work. But a common blind spot is right at the beginning: the problem statement. No matter how well we do at solving a problem, if we solve the wrong problem it was a waste of effort—and lean is about eliminating waste! We must be sure we are solving the right problem. Often, engineers make things more complicated than necessary. Consider the example of the NASA space pen. During the 1960s, NASA focused a major program on developing a pen that would write in zero gravity, while the Soviet space program used the much simpler and already-invented pencil. I don’t know for sure because I wasn’t there, but I strongly suspect this came about because of a miss in the problem statement. The Americans were working on this problem: How do we get a pen to write in zero gravity? The Soviets were working on a different problem: How do we write in zero gravity? It seems like such a small, subtle difference, but it had a huge impact on what work followed. The problem statement establishes our trajectory. If two people depart the same location on a trip, and only 5 degrees separates their trajectory, they will be in drastically different places in a matter of hours. We underestimate how powerful the problem statement can be, and that is pitfall number one. We

64 ASSEMBLY / July 2009 www.assemblymag.com

must respect the impact of the right problem statement. Wrong trajectory; wrong destination. Consider the difference in impact from two very similar problem statements: How do I get Joe to be a team player or, how do I develop a working relationship with Joe? The first problem statement is all about the other person, but the second problem

problem statement at least 50 percent of the time. The third pitfall in problem statements is jumping the gun on too many assumptions before the problem statement is created. We insert unexamined causes and solutions into the problem statement, closing us off to many possibilities. The earlier example of “we don’t have enough ovens” is an example of putting the solution in the problem statement. There is only one solution to that problem—buy more ovens. It immediately closes you off to many possibilities. When we assume too much too early, we limit what we can learn through observation and examination. I have two recommendations for improving problem statement development. The first is to write down the problem statement. Seeing the words on paper or, even better, on a whiteboard, will be a big help in evaluating and improving the problem statement. The second is to pause and ask for input, or offer coaching, on the problem statement before going too far. Ask your team, “Are we sure we have the right problem statement?” This will increase critical thinking significantly. Start with your own problems—write them down and get input. Lean begins with you!

Before you start down a path, make sure you’re setting off on the correct journey. Wrong trajectory; wrong destination. statement includes the problem owner, giving that person infinitely more power to solve this problem. Here’s another example: We don’t have enough ovens or, we don’t have enough oven capacity. The first problem statement only leads you to buy more ovens. The second helps focus on how you might be wasting oven capacity. The second pitfall is getting locked into the problem statement as though it is written on a stone tablet. We must be willing to adjust our problem statements. This doesn’t mean our original problem statement was wrong. Writing a problem statement is an iterative process—problem statements are changed because we learn stuff through the process of examining the problem. In my experience of coaching executives on lean thinking, we have to modify a

Email Jamie with comments via [email protected]. For his recommended books see tinyurl.com/leadinglean

SCREWDRIVING TECHNOLOGY

AUTOMATION

AIR MOTORS

POWER TOOLS

V E R S A T I L E M I N I M A T® - E INLINE HIGH TORQUE —— Up to 160 inch lbs torque capacity —— Torque-Holding-Time which compensates for relaxing joints —— Push to Start —— Ergonomic Design —— Non Slip Housing

[

SFM with a Minimat®-E mounted to a rotary index table

HANDHELD MINIMAT ®- E Angle-Head

Now available with up to

221 in. lbs. torque

MINIMAT ®- E Servo Now available with up to

531 in.lbs. torque

PISTOLGRIP

STATIONARY MINIMAT ®- E

[

Now available with up to

Angle-Head

159 in.lbs. torque

MINIMAT ®- E Servo Now available with up to

2,400 in.lbs. torque

—— All the functions of the original inline Minimat®-E —— Light Weight - starting at 1.28 lbs —— Ergonomic Design —— Trigger Start —— Non Slip Housing

DEPRAG, INC. 640 Hembry Street Lewisville, Texas 75057-4726 972 221 8731 main 972 221 8163 fax Catalog request: catalog@ depragusa.com General e-mail: mailbox@ depragusa.com

aqy ISO 9001 CERTIFIED

w w w. d e p r a g u s a . c o m

TOLL FREE 800 4 DEPRAG