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ASSEMBLY
August 2009
www.assemblymag.com
Auto Supplier Rides Winds of Change pg 14
Ophthalmic Assembly 22 Marking Dots, Stripes 30 Selective Soldering
34
ATExpo Preview
37
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August 2009
Vol. 52, No. 9
22
ASSEMBLY 66
COVER STORY
30
14 Automotive Supplier Rides Winds of Change 䡵
When a Nevada startup went looking for a manufacturer to assemble a new type of wind turbine, automotive supplier MasTech Manufacturing leapt at the opportunity.—John Sprovieri
34
FEATURES
DEPARTMENTS
䡵 22 Better One or Better Two?
Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ophthalmic device manufacturers keep an eye on new technology.—Austin Weber
䡵 30 When All You Need Is a Dot
Marking parts with colored inks or stains is a fast, easy way to differentiate between similar-looking components, indicate pass-fail status or confirm that a specific process has been performed.—John Keating and Claude Bergeron
34 Riding the Mini Wave 䡵
Automated selective soldering technology saves EMS facilities time and money.—Reed Gaither
37 Don’t Miss the Big Show 䡵
Find the tools your company needs to succeed at ATExpo 2009.—Adam Cort
Time to back health care reform.—John Sprovieri
Automation Profiles . . . . . . . . . . . . . . . . . . 8 System handles fragile components.—John Sprovieri
Quality in Assembly . . . . . . . . . . . . . . . . . . 9 Software helps assemblers manage quality tasks. —John Sprovieri
We Fed It . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 System feeds, assembles springs.—John Sprovieri
New & Noteworthy . . . . . . . . . . . . . . . . . . 12 All-purpose gloves made from bamboo.
Assembly Lines . . . . . . . . . . . . . . . . . . . . . 16 Group launches wind energy data base.
Assembly in Action . . . . . . . . . . . . . . . . . . 18 Single-cable camera maximizes efficiency.
Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Classified . . . . . . . . . . . . . . . . . . . . . . . . . . 46
NEXT MONTH
Cover photo courtesy Mariah Power
2 ASSEMBLY / August 2009 www.assemblymag.com
Automating Battery Assembly Robot Guidance Assembling With Lockbolts Assemblers Get a Lift
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The ‘Holy Grail’ of Ophthalmic Devices Engineers are developing an artificial retina that includes 60 implanted electrodes to help patients with impaired vision.
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Editorial
ASSEMBLY
Time for Health Care Reform
R
ecently, while cutting some fruit for breakfast, I nearly sliced off the tip of my left index finger. After much bleeding, abundant foul language, and a trip to the emergency room, I’m happy to report the finger was saved. Including a tetanus shot and skin glue, the bill for my mishap totaled an astounding $982. I shudder to think of the bill had I been in a serious accident. Thankfully, I have health insurance, but how long will that continue when treatment for a simple cut costs nearly $1,000? Almost all U.S. manufacturers offer health benefits to their employees, but the rising cost of those benefits is impairing their ability to hire workers, battle overseas competitors, develop new products, and invest in assembly technology. Employer-sponsored health insurance premiums have nearly doubled since 2000, a rate three times faster than wages. In 2008, the average premium for a family plan purchased through an employer was $12,680, which is nearly the annual earnings of a full-time minimum wage job. According to a 2008 survey conducted by the National Association of Manufacturers, 55 percent of small and midsized manufacturers reported that their health care costs increased by more than 10 percent during the past year. The 2008 election seems finally to have goaded Congress to action. In July, the House and Senate released draft reform bills. The bills are too big to be elaborated here, but here are a few key provisions. People who get insurance through their employer would retain that coverage. A new Health Insurance Exchange would be created so small employers and uninsured individuals could comparison shop among private and public insurers. Over time, the exchange would be opened up to all employers as another choice for covering their employees. Premium subsidies would be provided to individuals and families with low and moderate incomes. The measure is expected to cost $1 trillion over 10 years, a sobering number to be sure. It will be paid for with a mix of tax hikes and spending cuts on programs like Medicare. The House plan would apply an income tax surcharge on the wealthiest Americans. Another possibility is to limit the tax exemption on the most expensive health benefits plans from employers. Just as there can be no one solution to our increasing energy demands, health care reform must take a multipronged approach to the myriad factors that drive up costs. That means legislators on both sides of the aisle must swallow some bitter medicine. Sorry, Democrats, tort reform must be part of the health care bill. Too bad, Republicans, but a public option should be included in the insurance exchange. Whatever bill emerges from Congress—and we must demand a legitimate proposal this year—manufacturers should get behind it. The worst we can do is nothing.
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Automation Profiles
System Handles Fragile Components The glass ampoule is only 0.004 inch thick and very fragile.
When designing this system to assemble an adhesive applicator, engineers knew that glass and adhesive can and will get everywhere that they do not expect it.
H
andling glass can be challenging for any automation project. Actuators and grippers have no appreciation for the delicacy of an object. Glass parts in the wrong place at the wrong time are no match for hardened steel. Allied Automation has designed several systems that process thin glass containers safely and efficiently at high speeds. So when a medical manufacturer approached Allied to build a system to assemble an adhesive applicator, the company knew how to get the job done. Besides the adhesive itself, the applicator consists of a plastic swab tube, a glass ampoule and a plastic filter tip. A solvent bonds the filter to the tube. The ampoule is only 0.004 inch thick and very fragile. In this profile, Allied’s president, Jeff Graham, and engineering manager, Nathan Marshall, describe how the machine works. For more information, visit www.alliedautomation.com or call 919-362-4440. Describe the system. The machine has two components: an eight-station rotary dial and a recirculating puck conveyor. The dial is equipped with removable nests that hold four parts each. Each puck carries eight parts, and the conveyor accommodates 800 parts. The first station places four tubes in a nest and inspects for them presence and height. The second station lifts the tubes, supports them from the inside, and punches vent holes, depending on the product. (A product variant does not require vent holes.) The third station gently places the ampoules into each tube. Tooling at this station confirms the presence, length and integrity
8 ASSEMBLY / August 2009 www.assemblymag.com
of the glass. At station four, the filters are pressed into the tubes to complete the assembly and retain the ampoule. The fifth position was intentionally left free of tooling to facilitate access to the machine for cleaning and maintenance—an often-overlooked part of sound machine design. The sixth position inspects and records the assembled height of the product. This is done with linear variable displacement transducers. At station seven, good assemblies are off-loaded to the conveyor, where the solvent is applied and cured. The solvent is dispensed with a resolution of ±0.1 microliter. Bad assemblies are indexed to station eight, where they are deposited in a bin. What are the dimensions of the assembly? The machine handles two different product sizes. One is 52 millimeters long; the other is 72 millimeters long. Both are 8 millimeters in diameter. What equipment feeds the parts? Vibratory bowls with bulk hoppers feed the tubes and filters. The ampoules are fed manually. We also had to develop innovative ways to deal with the static electricity generated when feeding thin plastic parts. What inspections are included? All parts of the assembly are inspected for presence, orientation and assembled height. Inspections are performed with photoelectric sensors, capacitive proximity sensors and linear encoder-based contact probes. Additional sensors monitor the level and displacement of solvent, as well as the correct position of every actuator on the machine during operation. What is the production rate? 4,200 parts per hour. Only two people operate the entire system. Can the system accommodate variants? The system handles two different product sizes both with and without vent holes. Changeover is fully automatic. The product to be assembled is selected through the touch-screen, and all machine adjustments are made automatically. What was the most challenging aspect of building the system? The system must handle an ampoule every second without breaking any, and it must be easily accessible for cleanup when ampoules do break. It was critical to the success of the project that we understood that glass and adhesive can and will get everywhere that you do not expect it. We used chemical- and corrosion-resistant materials throughout the machine. The system is enclosed with tempered safety glass, so the windows stay clear even after cleaning with aggressive chemicals. All pneumatic actuators are equipped with corrosion-resistant rods. The system also had to comply with FDA requirements and clean-room specifications. A 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 sprovierij@bnpmedia. com, or call 630-694-4012.
Q
UALITY in ASSEMBLY
Software Helps Assemblers Manage Quality Tasks
I
n these days of far-flung supply chains and multiple assembly locations, even small and midsized manufacturers can have difficulty keeping everyone in their organizations on the same page. If a new standard or regulation affects your assembly process, can you be certain everyone gets the message? If an assembly-related defect is reported in the field, can you be sure the mistake isn’t repeated? You can, with web-based enterprise compliance and quality management software, says Nikki Willett, vice president of marketing and regulatory affairs at Pilgrim Software in Tampa, FL. Pilgrim’s product consists of seven interrelated, customizable modules that cover audit management, training and certification, calibration and maintenance, s u p p l i e r q u a l i t y, document management, complaint handling, and corrective and preventive action Web-based enterprise (CAPA) management. A key feature is the softcompliance and quality ware’s ability to integrate with other software, management software can such as enterprise resource planning systems, help assemblers address manufacturing execution systems, product life quality problems whenever cycle management software, human resources and wherever they occur. software, and call-center systems. Photo courtesy CEA The top priority of any manufacturer is to Technologies Inc. address quality problems whenever and wherever they occur. The CAPA management module captures these problems from multiple sources. “It can be a customer complaint,” says Willett. “It For reprints of this can come from your MES, because of a problem article, please contact on the shop floor. It may be an issue with incomCindy Williams at ing parts from a supplier. It may come from a [email protected] piece of equipment that’s out of spec.” or 610-436-4220 ext. 8516. When a problem is identified, a number of decisions need to be made quickly. Does the production lot need to be contained? Has it already entered the distribution pipeline? Software tracks ■ By John Sprovieri it down. In the case of a medical device, the software can also generate an electronic report for Editor
When updated instructions are logged into the system, the software alerts every operator to the new procedures.
the Food and Drug Administration. At that point, managers can think about identifying the root cause of the problem and how to correct it. Say, for example, an operator was using a machine incorrectly because the work instructions were out of date. The CAPA module can trigger a request to update the instructions in the document management module. The “owner” of the document would know to update the instructions and get any necessary approvals. When the updated instructions are logged into the system, the training and certification module is alerted to ensure that every operator who uses that machine knows the new procedures. This can be as simple has having each operator sign off on the new instructions. “Or, you may want to have the manager confirm that the operators have read it,” says Willett. “Operators may have to go through a checklist or take a small exam. They may even need classroom or online training. ...And because our software can be integrated with other business software, employee records can be automatically updated to reflect that they have completed the training, which they may need for their job certification.” Perhaps the cause of the problem wasn’t an outdated work instruction, but a machine that was out of specification. The calibration and maintenance module can tell management when the machine was last calibrated or serviced, and it can notify maintenance personnel to make an adjustment or replace a part. If the problem was faulty parts from a supplier, the supplier quality module gets triggered. “That could impact the rating of the supplier,” says Willett. “You may want to requalify that supplier. You may even want to change suppliers.” If ISO or FDA certification is necessary, the audit management module can help engineers prepare for audits and deal with their findings. “Auditors will come through with their questions and checklists,” says Willett. “They may find some issues and...make recommendations for improvement. Engineers can use the software to enter their plans for correcting those issues. Some of the auditor’s findings may be so critical that engineers may want to escalate to a A CAPA.”
www.assemblymag.com August 2009 / ASSE M B LY 9
WE FED IT
System Feeds, Assembles Springs 䡲 By John Sprovieri Editor
S
prings are tough to feed. They’re flexible, and they tangle easily. Centricity Corp. has developed a machine, called the Versa-Stack, that overcomes the challenges of feeding and assembling springs and other tubular parts. Recently, the machine was put to the test. It had to stack three cylindrical parts—a ring formed from steel wire, a metal tube, and a small or large coil spring—and place the stack into a larger assembly. The OD of each part was approximately 0.15 inch; the ID was 0.1 inch. The Versa-Stack consists of a vertically oriented servo-driven rotary indexer fitted with a custom dial plate. Mounted radially around the edge of the plate are 35 replaceable pins. Above the plate are two vibratory bowl feeders and two spring feeders fitted with Centricity’s Feedscape systems. The Feedscape is designed to feed parts with The Versa-Stack consists of a servoa high diameter-to-length ratio, such as washers, driven rotary indexer with a custom dial plate. Mounted radially around the edge retaining rings, wave washers, Belleville springs, of the plate are pins for holding tubular seals and bearings. Instead of handling parts by their outer surfaces, it handles parts by their inside parts. Photo courtesy Centricity Corp.
surfaces. The parts are threaded onto a rod and secured by a series of alternating jaws. Parts are free to travel down the rod as the jaws open and close. This maintains control of the part at all times. There is no chance for parts to flip, shingle or fall off. The Feedscape does not require a vibratory inline track, and tooling is inexpensive and flexible. As the dial indexes clockwise to the 11:00 position, a ring is fed from the bowl to a Feedscape, which drops it onto a pin. The dial then indexes to the next position, where the tube is dropped onto the same pin. Next, the dial indexes to the final position, where the small spring is dropped onto the pin. If the assembly requires the large spring, the first spring feeder is bypassed and the second feeder is activated. The stacks are held in place by an integrated retaining system until they reach the 6:00 position. At that point, the stack is threaded onto another Feedscape mechanism, which passes it off to a robot at a rate of 15 per minute. For more information, call 330-545-5624 or visit www.centricity.net.
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Modular Automatic Coiling System Is Flexible The modular AutoCoiling System can automatically coil, bind and batch long wires, replacing lengthy conveyors and freeing up valuable floor space. Due to its flexible and modular design, including a separate power supply, the system can be retrofitted to CrimpCenter series machines in the field. It is possible to coil single-wire applications with or without seals or terminals on either end. Accuracy is assured by continuous wire length measurement using a closed-loop system. Schleuniger 603-668-8117 www.schleuniger-na.com See us at ATExpo, Booth 446 www.assemblymag.com August 2009 / ASSE M B LY 13
Automotive Supplier Rides the Winds of Change 䡲 By John Sprovieri Editor
N
ot that long ago, MasTech Manufacturing in Manistee, MI, was riding high. A supplier of conveyors, material handling equipment and welding cells for the automotive industry, the company had won some major contracts, including lines at Freightliner in Cleveland, NC, and BMW in Spartanburg, SC. But then the automotive industry hit the skids. MasTech’s workforce went from approximately 50 people in mid-2008 down to just three. If the company were to survive, it would have to diversify. So, when Reno, NV, startup Mariah Power went looking for a manufacturer to build its new wind turbine for residential and light commercial use, MasTech leapt at the opportunity. It signed a contract with Mariah Power in December 2008, and began converting its 30,000-square-foot facility to make the turbine, a vertical-axis design called the Windspire. All totaled, MasTech spent some $1.5 million on new equipment. “We built robotic [and] manual welding tools,” says John Holcomb, MasTech’s general manager. “We built custom material handling equipment and racking. We bought new machine tools.”
“It’s been our desire since Day 1 to make the largest economic impact in the smallest geographical area.” —John Holcomb, MasTech Production began in April. Since then, the company has been assembling 100 turbines per month—a number that could increase to 1,000 per month within a few years. MasTech has shipped Windspires throughout the United States, as well as internationally, including Israel, Denmark, France and the Netherlands. The company has hired back all the employees who were laid off, and even added a few more. By the end of 2009, the company could have a workforce of 75 to 80 people. “By the end of next year, we hope to employ approximately 120 people,” says Holcomb. “If we start selling more overseas, we could potentially have 500 to 600 jobs in five years.” The Windspire is 30 feet tall and 4 feet wide. It includes a highefficiency generator, an inverter, a hinged monopole and a wireless performance monitor. The 1.2-kilowatt machine will produce approximately 2,000 kilowatt-hours per year in winds averaging 12 mph. From the start, MasTech included local suppliers in the endeavor.
14 ASSEMBLY / August 2009 www.assemblymag.com
Since April, MasTech has been assembling 100 turbines per month—a number that could increase to 1,000 per month within a few years. Photo courtesy Mariah Power
The turbine’s aluminum airfoils are produced by Whitehall Industries Inc. in Ludington, MI. Steel parts come from Alro Steel Corp. in Jackson, MI. The inverters are assembled by Amptech Inc. in Free Soil, MI. Boxes and crates are made by Norton Packaging Corp. in Grand Haven, MI. At least three other Michigan companies are also part of the supply chain. “It’s been our desire since Day 1 to make the largest economic impact in the smallest geographical area,” says Holcomb. “The only components that come from outside the United States are the rare earth magnets, which come from China, but that’s where neodymium is mined.” Holcomb emphasizes that his company’s turnaround should not be considered unique. “We’ve proven that, given the right tools and the right attitude, American workers can compete in the global market by supplying not only a cost-effective product, but a superior product,” he says. “Anyone can do it. We have the technology. If we reapply it and leverage it in new, innovative directions, we can compete with anybody.” 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.
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Assembly Lines
Inventions
Mergers Forecasts New facilities Group Launches Wind Energy Database
The Great Lakes WIND Network has created an online database to help wind energy companies locate suppliers and other renewable energy organizations.
CLEVELAND—The Great Lakes WIND Network, an international wind energy supply chain advisory group, has launched a new web-based WIND Energy Supply Chain Database and Mapping System, available online at http://maps.glwn.org/wind/, to promote the growth of the wind power industry. The site features an interactive map and a searchable wind supply chain database containing the profiles of more than 1,000 manufacturers and organizations in the United States, Canada and Mexico that actively serve the emerging wind industry. Designed to facilitate customer-supplier relationships, the system quickly connects manufacturers and suppliers with OEMs, economic development officials, consultants and other wind power supply-chain partners. “The wind energy sector is the fastest growing industry in North America. By linking buyers, sellers and other industry partners, we believe this system can be a catalyst for business expansion, investment and new jobs,” says network director Ed Weston. “We are very excited at the prospect of being able to service our global network with a single site that supports supply chain needs.” Access to the site is free. To register with the database, visit www.glwn.org, select “Get Listed,” and complete a Wind Capabilities Profile to start the registration process. 16 ASSEMBLY / August 2009 www.assemblymag.com
Deere & Co. Planning Russian Expansion MOLINE, IL—Deere & Co. says it is prepared to “significantly expand its farm, forestry and construction operations in Russia,” as part of the company’s long-term commitment to the region. The remarks came during a recent Russia-USA Business Forum in Moscow, which took place at the same time President Obama was meeting with Russian president Dmitry Medvedev. “We share the vision that Russia can make a significant and sustainable contribution to help meet the world’s growing demand for food, energy and forest products,” says Deere CEO Samual Allen. “John Deere is working to expand its Russian manufacturing capacity for agricultural equipment by early 2010. Ultimately, with the support of the government of the Russian Federation, Deere could envision a series of significant investments over the next five to seven years in expanded capacity for manufacturing and supporting all types of Deere equipment.”
EFD Inc. Wins Solar Award EAST PROVIDENCE, RI— Dispensing equipment manufacturer EFD Inc., a subsidiary of Nordson Corp., has won the 2009 International Solar Cell Award for best technical product. Presented at the 2009 InterSolar Exhibition in Munich, Germany, the award comes in recognition of the company’s new PV cell ribbon and
bus bar attachment methodology: a point-to-point soldering process that uses a lead-free solder paste and flux mixture to attach string ribbon material to silver bus bars during solar module assembly. In addition to eliminating the need for precoating with a liquid flux, the process creates a robust solder joint with minimal microcrack formation. The result is an increased lifespan for the solar modules in which it is used.
Kyzen Opening Malaysia Office NASHVILLE—Electronics cleaning products manufacturer Kyzen is opening a new sales and support facility in Penang, Malaysia, as part of an ongoing effort to increase the company’s market share in the Asia-Pacific region. “The possibility of a Kyzen facility in Southeast Asia has been under consideration for some time,” says Kyzen vice president Tom Forsythe. “Malaysia is an important hub for high value-added electronics and other high-technology manufacturing with a business friendly environment and, most importantly, with a highly educated, dedicated work force.” Founded in 1990, Kyzen provides cleaning products to a wide range of customers, including those in the electronics, metal finishing, medical device, semiconductor and optical components industries.
Volvo Kicks Off Fuel Cell Initiative GOTEBORG, Sweden—Volvo
group is teaming up with Midroc New Technology, the OCAS research center in Belgium and the Swedish Energy Agency to develop and produce a new generation of fuel cells for possible use in everything from trucks to boats. As part of the initiative, the three members are forming a new jointventure company called Powercell Sweden AB, based in Gothenburg, Sweden. The $25 million effort is expected to create some 100 new jobs over the next three years.
Interior Components Company Expanding in Midwest VALPARAISO, IN—UGN Inc., a manufacturer of interior trim products for the automotive industry, will invest about $3 million to expand its production capacity in northern Indiana. The company says it will also add another 100 employees to its payroll by 2014. “UGN continues to grow and celebrate successes in a very challenging economic environment,” says company CEO Randy Khalaf. “Our Valparaiso facility is seeing incredible expansion and is well positioned with new products and technology to see further growth once the global economy starts to show signs of recovery.” Founded in 1986, the company is adding 10,000 square feet of manufacturing space to accommodate a new contract to produce interior components for both luxury automobiles and SUVs. The company also provides components for small trucks.
Power Tool Demand Rising CLEVELAND—Despite the current recession, global demand for power tools is expected to increase 7 percent annually through 2013, according to a recent study by The Freedonia Group. Total annual demand is expected to be about $29 billion by the
end of the study period. The U.S. market will continue to be the strongest, accounting for slightly over a third of total demand. In addition to responding to an eventual turnaround of the current housing crisis, the U.S. market is also expected to benefit from the introduction of new and improved products, such as cordless electric tools. Freedonia researchers say there will also be healthy demand in Brazil, Russia, India and China, with demand in China and India rising about 6 percent annually in the course of the study period. For more on the study, visit www.freedoniagroup.com.
Nordic Windpower Secures DOE Loan BERKELEY, CA—The U.S. Department of Energy has approved a $16 million loan to help Nordic Windpower USA Inc. expand its production facility in Pocatello, ID. The loan is being supported through the 2009 American Recovery and Reinvestment Act, signed into law by President Obama in February. Nordic Windpower manufactures two-bladed, utility-scale wind turbines featuring a flexible “teeterhub” that helps dissipate the force of turbulent winds that would otherwise cause undue wear on the system’s drive train. As part of the expansion, Nordic plans to add another 75 employees to its payroll. “Nordic’s expansion will create new and skilled green jobs to boost the economy and help meet America’s growing energy needs with clean wind power,” says Tom Carbone, CEO of Nordic Windpower. “We appreciate DOE’s vote of confidence in our innovative technology and our business model.”
manufacturer Stäubli Robotics is teaming up with the engineering and integration company Rixan Associates Inc. to coordinate activities in the areas of marketing and sales, with an emphasis on robotic automation services, engineering services, components, software and training. “We are building the future by bringing two world-class organizations together in forming a strategic partnership. This partnership will reinforce our mutual customer-centric commitment in providing first class service and support to our customers,” says Stäubli Robotics division manager Joe Gemma. “We are excited about this new partnership,” says Rixan President Stephen Harris. “Rixan needed robots with higher payloads, faster cycle times and robots that had more application-specific features. Stäubli robots fulfill those needs and will provide our customers with leading-edge technology, high reliability and a worldwide support network.”
Assembly Event Records Strong Attendance NEW YORK—Despite a challenging economy, Canon Communications says attendance was up 3 percent at its recent assembly and medical device trade event in New York.
In all, some 24,000 buyers were on hand for the co-located MD&M East, EastPack, Automation Technology Expo East, Green Manufacturing Expo and Atlantic Design & Manufacturing shows held at the Javits Convention Center in June. “A number of our exhibitors expected that attendance would be down because of the current state of the economy,” says Canon Communications CEO Charles G. McCurdy. “Instead, the success of this event has generated considerable optimism among them about the enduring business vitality of key advanced manufacturing segments, most notably medical devices.” As further evidence of this fact, McCurdy says about two-thirds of the event’s 1,000 exhibitors have already contracted for space in the 2010 show. “The MD&M East Show allowed us to land more than 90 leads, of which 75 percent or more have immediate needs for our products and services,” says Ken Jenkins, president of Ohio-based mold maker Pleasant Precision Inc. “I have displayed at more than 15 trade shows in the past 10 years, and the MD&M East Show provided more substantial leads than all of the other shows together.” For more on Canon Communications, which also organizes the Assembly Technology Expo in Rosemont, IL, sponsored by ASSEMBLY magazine, visit www.cancom.com.
Stäubli, Rixan Associates Joining Forces DUNCAN,
SC—Robotics
Canon Communications’ trade show in New York continues to grow, despite the tough economic climate. www.assemblymag.com August 2009 / ASSE M B LY 17
Assembly in Action
Single-Cable Camera Maximizes Efficiency
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By eliminating the need for any additional cables, the camera minimizes the risk of cable fatigue and greatly improves the integrity of the vision system.
For reprints of any Assembly in Action article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.
omau Group, a subsidiary of Fiat Spa, builds automated production machines for a wide range of customers, including those in the automotive industry. The company also manufactures turnkey automated assembly systems, robots, weld guns, conveyors, recognition software and other automation components. Recently, engineers at the company’s North American headquarters in Southfield, MI, developed what they call VersaVision II software as an upgrade to the company’s existing robotic guidance systems. The new software allows a robot to both pick up parts and then position them in space using a single machine-vision camera, as opposed to multiple cameras. The software can be used with any GigE camera or robot currently on the market. By reducing the number of cameras, the system helps assemblers reduce costs. “The VersaVision II program provides our robots true visual recognition,” says Comau product development engineer Max Falcone. “The software emulates the visual cortex of the human brain, teaching the system to recognize an object the same way you would teach an infant. We show the system an object by taking a picture of the object and naming it. All of the information pertaining to that object is
18 ASSEMBLY / August 2009 www.assemblymag.com
stored into the system’s memory, which allows the system to recognize the target part and maneuver a servo-actuated manipulator to pick, place or work on that object.” To make the system as effective and efficient as possible, Comau engineers wanted to reduce the amount of cabling connecting the robot-mounted camera to the robot controller. Standard GigE cameras require three cables: one for communications, one for power and one to trigger the camera to take a picture. Three cables means three times the opportunity for failure in a single camera application.
Comau engineers wanted to reduce the amount of cabling connecting the robot-mounted camera to the robot controller. “To make our robotic guidance systems as reliable and cost-effective as possible, we wanted to take our design one step further,” says Comau robotics and vision products manager Tony Ventura. “Not only did we need to reduce the number of cameras in our systems, we wanted to reduce the chances of system failure associated with cabling. The more cables located on a robot, the higher the risk of cable failure.” To solve the problem, Comau incorporated a TXG camera with power over GigE cabling from Baumer Ltd., a manufacturer of sensors, motioncontrol equipment and machine vision. In the Comau application, the camera includes a specially developed industrial power injector module or Ethernet
off parts that are incorrectly To develop the application, Rixan oriented and allow through engineers first used the Melfa-Vision only those parts that are po- software to calibrate the robot in relasitioned correctly. tion to the feeder. They then put a part Historically, because of in the robot gripper and “jogged” the the various hard-tooled robot over to the feeder where it set the orientation features that part down on the plenum. In this way are required, this kind of engineers “taught” the robot to pick up equipment has been very the part in this orientation and at this part-specific. However, the point on the plenum. robotics company Rixan Once the robot had been taught how Associates Inc. has devel- to pick up the part, Rixan’s engineers oped a new flexible vibrato- used the Cognex camera’s PatFind The new software allows a robot to both pick up parts and ry bowl feeder that includes object-location tool to draw a rectangle position them in space using a single camera. a robot and machine vision around the part on the screen, thereby system to orient multiple allowing the vision system to automatiswitch that provides power down a Cat6 parts using a single system. cally recognize the part as it moves Ethernet cable at distances up to 100 Rixan originally developed the across the plenum. meters. By eliminating the need for any system to load dozens of different In operation, when it sees a part, the additional cables, the Power over GigE aerospace fasteners into a press, a system first sends a signal to stop the Camera minimizes the risk of cable fa- task that was previously tigue and greatly improves the integrity performed by hand and of a vision system. would have otherwise According to Falcone, Comau also required installing many liked the camera because of its robust different feeders to design and performance features. “The automate. camera is neat, complete and well engiThe new system emneered. The lock-style connections are ploys a vibratory bowl strong, reliable, industrially accepted feeder that randomly presM8 connectors. The integrated UV ents the parts to the vision filter mounted in front of the camera’s system, which in turn, face eliminates the need to buy and in- stops the feeder when it stall a separate filter to show true col- sees the correct part in ors. This high-quality camera allows us the correct orientation so to provide our customers with an over- that a robot can load the all lower cost system,” he says. part into the press. The The system employs a vibratory bowl feeder that randomly For more on machine vision, visit parts are presented on a presents the parts to the vision system, which in turn, stops the feeder when it sees the correct part in the correct orientation. www.baumerelectric.com/usa or call semitransparent, backlit 800-937-9336. plenum, so the vision sysFor more on automation, call 248- tem can easily identify them. The parts feeder. After the feeder has stopped, the 353-8888 or visit www.comauinc.com. that are not picked automatically recycle vision system acquires one last image to into the bowl. The result has been a 20 determine the exact position of the part percent increase in productivity and one and calculate its angle of presentation. less operator to tend the press. The robot then moves to the location Critical to the success of the system of the part, twists its wrist to match the has been its In-Sight 5401 vision sys- part’s orientation, picks up the part and raditional vibratory bowl feeders use tem from machine vision manufacturer sends a signal to restart the feeder. a helical shelf-like inclined ramp Cognex Corp., which is integrated with Most of the parts in the aerospace winding up from the bottom of a bowl an RV-6SL-S11 robot and Melfa-Vision fastener application are symmetrical to a discharge passageway. The pas- software from Mitsubishi Electric. top to bottom so they can be identified sageway’s reciprocating motion pushes Rixan chose the In-Sight 5401 because from their silhouette alone. However, the parts up the ramp. Obstructions, of its processing power and the fact that in those instances where a part has two cutouts and other orienting devices are it can acquire up to 60 complete eight- distinct sides, the Cognex PatMax tool arranged along the passageway to topple bit images per second. can be used to recognize which side is
Vision Enables Feeder to Handle Multiple Parts
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Assembly in Action
up. Top-down lighting is used options like speed enhancefor parts in which pattern ment, next-generation unrecognition is required. White derstencil cleaning technollight is used for some parts, ogy and automatic board while glare-free polarized support, as required. lighting is used for others. “It’s no coincidence that “A key to the success of DCI has been named to this application is the ease-ofFortune Small Business setup, accuracy and reliability magazine’s list of the fastest of the Cognex In-Sight vision growing small companies sensors,” says Rixan Associfor the past two consecuates President Stephen Hartive years,” says DCIs viceris. “The PatMax tool that we president of business develuse to recognize part features opment Jay Gillam. “When is much faster and more acyour top priority is ensurcurate than other comparable ing your customers receive industry tools that we have outstanding service and suseen. The easy integration beperior quality products on tween Cognex vision sensors time every time, business The screen printer’s scalability means it can be modified to meet DCI and Mitsubishi robots drasti- Inc.’s future manufacturing needs as well as those in the present. success is inevitable. Our cally reduces the amount of addition of DEK’s Horizon time required to develop vision-enabled system’s quick setup and changeover 03i is just one more example of this robot applications and in most cases times, as well as its new HawkEye print commitment.” eliminates the need for writing a single verification inspection feature. For more on custom electronics manline of code.” “We evaluated several screen printing ufacturing, call 888-824-9412 or visit For more on machine vision, call 508- systems,” Morgan says. “The capability www.dciincorporated.com. 650-3000 or visit www.cognex.com. of DEK’s Horizon 03i coupled with For more on screen printing systems, For more on parts feeding and the staff’s depth of knowledge and visit www.dek.com. automation, call 937-438-3005 or visit process expertise made our decision an www.rixan.com. easy one. With the Horizon platform’s new scalability, future-proofing and ability to customize, we can modify the system to meet our manufacturing ne of the goals of the school of requirements as our business changes architecture at the University of and grows.” CI Inc., in Olathe, KS, designs and DEK’s entire manufactures electronics compo- Horizon line of nents and subassemblies for custom- screen printers ers in a wide range of industries. The includes mocompany specializes in the design and torized stenmanufacture of specialized custom liq- cil alignment, uid crystal displays, light emitting di- fast product ode displays and operator interfaces. changeover, 2.0 Recently, the company expanded its Cpk print proelectronics manufacturing capacity by cess capability implementing a new Horizon 03i fully and Six Sigma automatic screen-printing system from production perelectronics assembly equipment manu- formance. The facturer DEK USA Inc. system’s InAccording to DCI chief operating stinctiv V9 user officer Mike Morgan, the company interface allows went with the Horizon 03i because of manufacturers When the school of architecture at the University of North Carolina went its high print quality and ease of use. to seamlessly in- shopping for new workbenches, it ended up going with a set of stations Morgan says his company also likes the tegrate advanced from industrial workstation manufacturer Lista International.
Screen Printer Adapts to Changing Needs
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Workbenches Harmonize With Design Goals
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North Carolina in Charlotte is to help students “apply strategic thinking to environmental problems.” It was therefore only natural that when the school needed a new set of work desks, the students should take part in the selection process. “Our existing desks had worn out their welcome,” says Ken Lambla, dean of the university’s college of arts and architecture. “The old desks were custom-designed and custommade when we first occupied our building in 1991. They may have been sufficient then, but today they didn’t offer the kind of flexibility the students’ work demanded. Not only were the dimensions and ergonomics insufficient, but they were lacking in many key areas of functionality: no power supplies, no wheels for mobility, inadequate display surface, and serious storage limitations.” Ultimately, after consulting with a student-run focus group and putting the project out for bid, the college replaced more than 200 of its old desks with a set of Arlink workstations from industrial workbench and cabinet manufacturer Lista International Corp. According to Rich Preiss, the school’s director of laboratories, the school chose the Arlink workbenches because they were rugged, functional and aesthetically pleasing. Lambla adds that Lista was also very responsive in terms of meeting the school’s particular needs. “Being architects, we’re pretty detail driven,” he says. “We needed a company that was going to work with us on the exact details of fabrication as it relates to the experience we’ve had over the last 15 years. Lista brought a lot of knowledge to the table and demonstrated an ability to create custom application-specific solutions.” Lambla adds that the company was able to work within a narrow time frame, another reason the college went with the Arlink desks. “We needed somebody who could
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supply these workbenches within a very tight window of time—about eight weeks to be exact. This included about one week for delivery and installation,” he says. “At the university level, we call the money that’s left over from the annual budget ‘one-time money.’ This is what we were working with, and if
we didn’t use it by the given deadline, we’d lose it. Fortunately Lista came through, not only on time, but with completely assembled products. Many of the other bidders were delivering only parts. Lista provided a ready-to-use solution.” For more on workstations, call 800722-3020 or visit www.listaintl.com.
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ASSEMBLY
Medical Device Assembly
Better One or Better Two? Ophthalmic device manufacturers keep an eye on new technology.
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Because of the aging population, there will be a huge demand for ophthalmic devices over the next four decades. Photo courtesy Carl Zeiss Meditec AG
one of the most dynamic market segments in the medical device industry. An aging population, proposed federal healthcare reform and an increasing number of elective surgeries, such as Lasik treatment, is creating a huge demand for diagnostic instruments, surgical equipment, lasers, intraocular lens implants, shunts, artificial retinas and other products.
By Austin Weber Senior Editor
s most people age, they become wiser. But, gradual vision loss is something that even the smartest people in the world can’t avoid. That simple fact of life is good news for the ophthalmic device industry. Cataracts, glaucoma, macular degeneration, presbyopia, diabetic retinopathy, posterior uveitis and other visionrelated conditions make ophthalmology
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Approximately 50 percent of all adults in the United States don’t have 20/20 vision, because they are nearsighted, farsighted or have an astigmatism, which is an irregular curve of the cornea. By 2020, the number of people who are blind or have low vision is projected to increase dramatically. “Blindness or low vision affects 3.3 million Americans age 40 or over . . . and this figure [will] reach 5.5 million by the year 2020,” says Elias Zerhouni, M.D., director of the National Institutes of Health (Bethesda, MD), which operates the Eye Disease Prevalence Research Group and the National Eye Institute. “As our population lives longer, eye disease will be an ever greater concern. Low vision and blindness increase significantly with age, particularly in people over age 65.” A recent study conducted by RTI International (Research Triangle Park, NC) and the Centers for Disease Control and Prevention (Atlanta) predicts there will be a huge demand for ophthalmic devices over the next four decades. “The aging U.S. population will lead to a large increase in early and advanced age-related macular degeneration,” claims David Rein, a senior research economist at RTI. “By 2050, the number of people with early age-related macular degeneration will double to more than 17.8 million,” Rein points out. At the same time, he expects the number of cases of diabetic retinopathy, which is the leading cause of blindness among working-age adults in the United States, to increase from 5.5 million to 16 million.
“The good news is that medical technologies are changing rapidly,” says Rein. “Ten years ago, there were no treatments for age-related macular degeneration. With luck, tomorrow’s discoveries will lead to far greater reductions in visual impairment and blindness.” According to MedMarket Diligence LLC (Foothill Ranch, CA), the worldwide ophthalmic products market exceeds $22 billion and is growing at more than 10 percent annually. The industry is dominated by several major players, such as Abbott Medical Optics Inc. (Santa Ana, CA), Alcon Laboratories Inc. (Fort Worth, TX), Bausch & Lomb Inc. (Rochester, NY) and Carl Zeiss Meditec AG (Jena, Germany). However, numerous small start-up companies specialize in niche segments, such as cataract, corneal or refractive surgery. No matter the size of the company, ophthalmic manufacturers are focusing their efforts on making surgical procedures faster, easier, more accurate and more affordable. There’s also a growing trend toward drug-device combination products. Diagnostic Tools Traditionally, the ophthalmic industry is divided into two main segments: diagnostic instruments and surgical devices. Diagnostic instruments are used by ophthalmologists to examine their patients. They include refractors (the “better-one, better-two” device that’s used in conjunction with an eye chart), slit lamps (an upright microscope equipped with a bright light) and tonometers (a device that measures eye pressure). Ophthalmologists are always looking for equipment that makes them better clinicians. They want instruments that provide information that allows them to make better diagnoses and more efficient treatment decisions in a patient-friendly manner. “The latest trend is toward noninvasive diagnostic imaging,” says Andrew Shatz, M.D., an ophthalmologist at the Woolfson Eye Institute (Atlanta). “High-speed ultrasound
A wide variety of diagnostic instruments are used by ophthalmologists to examine patients, such as slit lamps. Photo courtesy National Eye Institute
and scanning laser tomography are both giving increasingly sharper resolution of the microscopic structures of the eye, allowing for a more detailed view of pathology. “This has also allowed us to visualize the relationship between the different regions of the eye in a way we have never been able to before, without having to resort to intravenous dye injection,” explains Shatz. “More doctors are adopting technology that allows us to image the back of the eye without the need for dilation.” “We now have incredibly precise
imaging devices called OCT (optical coherence tomography) that allow us to create microscopic images of structures inside the eye that were never before visible,” adds John Hovanesian, M.D., an ophthalmologist at Harvard Eye Associates (Laguna Hills, CA) and a clinical instructor at UCLA’s Jules Stein Eye Institute (Los Angeles). “This greatly aids in diagnosis of conditions like diabetic eye problems, eye tumors and macular degeneration.” An OCT allows an ophthalmologist to construct three-dimensional images of living eye tissue with better resolution
The human eye is a complex, delicate organ. Common back-of-the-eye diseases include age-related macular degeneration and glaucoma. Illustration courtesy American Academy of Ophthalmology www.assemblymag.com August 2009 / ASSE M B LY 23
Medical Device Assembly than a traditional MRI scan. the world’s first noninvaBetter yet, the procedure sive early detection device can be performed in a for cataracts, the leading doctor’s office instead of a cause of vision loss worldhospital. wide. The new device is Today’s new breed of based on a laser light techdiagnostic instruments use nique called dynamic light state-of-the-art technology scattering (DLS). to objectively measure and It was initially develquantify vision disorders. oped to analyze the For instance, engineers at growth of protein crystals Optos Inc. (Marlborough, in a zero-gravity space MA) recently developed environment. The tablea new type of imaging top DLS device is used device that provides an to detect the earliest damultra-widefield view age to lens proteins, trigof the retina. It allows gering an early warning ophthalmologists to see This telescopic implant is 4 millimeters long and contains two wide-angle glass for cataract formation and lenses. It is designed to treat age-related macular degeneration. Photo courtesy more than 80 percent of VisionCare Ophthlamic Technologies Inc. blindness. the retina, compared to a “Much of the work [in traditional camera that provides a much Researchers at the National Eye Insti- the diagnostic instrument field] is going narrower view—about 11 percent. The tute (Bethesda, MD) and the National into finding ways to treat presbyopia to device uses scanning coherent laser Aeronautics and Space Administration enable people to get rid of their reading light rather than full spectrum white (NASA, Washington, DC) recently glasses,” says James Ohneck, CEO of light that’s typically used by cameras adapted a compact fiber-optic probe Oculatek Inc. (Cleveland). The start-up and other forms of ophthalmoscopy. developed for the space program into company has developed a transscleral
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light therapy system that uses a low level of infrared light at a specific wavelength. “It helps strengthen the ciliary muscle, which weakens as the eye ages and is one of the factors that leads to the eye’s inability to accommodate,” Ohneck points out. “It is therapy, not surgery,” adds Ohneck. “The patient has several short therapy sessions where they look into a binocular while the eye is dosed with infrared light. The treatment does not harm the eye and there is no pain associated with the procedure. It’s unique because it is the first device of its kind to therapeutically treat presbyopia without an invasive surgical procedure. Newer technologies being developed involve implanting special lenses through a surgical procedure or modifying the shape of the eye to adjust vision.” Even noninvasive ophthalmic procedures must be cleared by the U.S. Food and Drug Administration (FDA, Washington, DC), which often hinders start-up manufacturers and prevents
asb08094dymax.indd 1
them from quickly ramping up production. For instance, Oculatek’s device is still undergoing trials with the FDA. If approved, it won’t be readily available to ophthalmologists for several more years. “The challenges around new devices are regulatory in nature, such as getting FDA approval and validating the efficacy through clinical trials,” says Ohneck, who holds a degree in electronic engineering. “This takes time and money. Investors are reluctant to put money into products that don’t have the trials, so it’s a chicken and egg; you need money to do clinicals, but you can’t get it until the clinicals are completed.” To reduce costs, many start-up manufacturers outsource assembly to third parties. For instance, Oculatek is working with Valtronic Technologies Inc. (Solon, OH). That allows Ohneck and his colleagues to focus their attention on product development. Ophthalmic devices are typically
assembled in clean rooms. Large manufacturers, such as Alcon, have recently been focusing their efforts on ergonomics and automation. Alcon’s Fort Worth plant recently celebrated its 50 anniversary, and the company is currently building a new facility in Singapore to supply the fast-growing Asian market. “In our more manual assembly areas, we have invested in adjustable workstations and eliminated microscopes to make our operators more comfortable,” says Melissa Mota, a company spokesperson. “In addition, we have invested heavily to automate mid- and higher-volume operations and products. Our focus has been on advancing our assembly processes to be flexible with high-mix automation, in order to satisfy increasing demand for our products.” Implantable Devices One of newest technological advances on the surgical side of the ophthalmic device industry is the correction of presbyopia, which affects 90 million people
See us at ATExpo, Booth 1233 www.assemblymag.com August 2009 / ASSE B LY 25 7/14/09M10:20:55 AM
Medical Device Assembly
An OCT allows ophthalmologists to construct three-dimensional images of living eye tissue with better resolution than a traditional MRI scan. Photo courtesy Carl Zeiss Meditec AG
in the United States, with multifocal and accommodating implants. “These not only improve distance vision without glasses, but also decrease the need for readers,” says Shatz. “This market has been heating up over the last few years. What has started out with three competing lens models will [eventually] blossom to 10 or more different
This fiber-optic probe uses NASA-developed technology to detect cataracts. Photo courtesy National Eye Institute
technologies, all aimed at achieving the holy grail of ophthalmology. “The new revolution is almost at hand,” claims Shatz. “Improved lens and cataract surgery technology, in combination with the baby-boomer generation now developing cataracts, has created the perfect breeding ground for presbyopic lens implants. This technology
will overtake laser vision correction as the primary means of correcting vision in the next five to 10 years.” Intraocular lenses (IOLs) are typically made of either acrylic or silicone. Early versions were made of an acrylic polymer called PMMA, which is what led to the discovery of using IOLs in cataract surgery.
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7/6/09 3:09:13 PM
with an IOL. The hybrid devices are designed to treat the most common postoperative complications, such as inflammation, infection and secondary cataracts. “Drug therapy ease of use is of considerable importance as the world’s population continues to age,” says Tracy Klein, CEO of Inson Medical Systems Inc. (Bellevue, WA). “There is a considerable opportunity to reformulate
INTRODUCING THE
older pharmaceuticals into implantable devices. Eye drops are the standard of care for most ophthalmic diseases, yet they have poor penetration into the eye and are inconvenient for patients to administer, often with four to six times per day dosing.” Klein’s company is developing frontof-the-eye drug delivery beads that are smaller than a grain of rice. “We plan to utilize this expertise on future products
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The latest trend in IOLs is toward corrective, foldable lenses that are structurally designed to minimize secondary cataracts from occurring. Most companies developing intraocular implants are focusing their efforts on devices that treat back-ofthe-eye diseases, such as glaucoma and acute macular degeneration. For instance, Alcon recently unveiled the third generation of its Restor lens. The multi-focal device contains 12 concentric “steps” around the optic zone of the lens, which appear as rings. They create different focusing levels from near to distant vision. The surgical procedure is painless and only takes about 20 minutes. Some ophthalmologists are recommending the procedure as an alternative to the more controversial Lasik treatment. In addition, engineers and doctors are currently developing polymeric drug delivery devices that are implanted at the time of cataract surgery along
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Medical Device Assembly
Ophthalmic devices, such as intraocular lenses, are typically assembled in clean rooms. Photo courtesy Carl Zeiss Meditec AG
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for back-of-the-eye applications,” he explains. “We are also in very early development discussions with potential partners who are interested in utilizing our technology to create IOLs capable of drug delivery.” Implantable intraocular lenses pose numerous manufacturing challenges. “The main challenge for us is to make a device small enough to be inserted with the lens, yet big enough to hold enough drug,” says Klein. “There are also technical challenges to overcome with existing injection molding techniques when making devices this small.” For instance, lenses must be extremely thin to be flexible and comfortable to patients. Klein believes the ophthalmic device industry may be able to adapt existing semiconductor manufacturing technology and equipment if devices get smaller. “[However], ophthalmic implantable devices must be as long-acting as possible for obvious reasons,” says Klein. “Therefore, they are unlikely to get much smaller. In addition, surgeons generally want devices they can retrieve if necessary.” “The goal at the moment is to achieve better efficacy with less invasive procedures,” notes Paul Ashton, M.D., president of pSivida Corp. (Watertown, MA). “There are a lot of blinding diseases for which there are no drug treatments yet approved. These diseases include dry age-related macular degeneration (AMD) and diabetic retinopathy.
See us at ATExpo, Booth 615 28 ASSEMBLY / August 2009 www.assemblymag.com
“Recently, there have been some drug treatments approved for wet-form AMD, but this typically consists of an injection into the eye every couple of months,” Ashton points out. “A [more] effective and less invasive treatment for this disease [would] be quite an advantage.” Ashton and his colleagues have recently developed a variety of ophthalmic devices for either implantation or injection into the eye. The devices are made from a proprietary porous silicon material. Vitrasert was the first sustained release device approved for back-ofthe-eye applications. It’s about the size of a pepper corn (6 millimeters long and 2.5 millimeters wide). The device is surgically implanted into the eye, where it releases drugs for six to eight months. “Because the drug is released directly into the eye, it requires approximately 20,000 times less drug than would be needed if given intravenously,” says Ashton. Retisert is a smaller device that is 5.25 millimeters long and 1.5 millimeters wide, or about the size of a grain of rice. It lasts 2.5 years after implantation into the eye. “As it releases its drug directly into the eye, it delivers about 200,000 times less drug than would be needed if the patient took the drug orally,” claims Ashton. It is the only FDA-approved treatment for posterior uveitis, a potentially blinding disease. “Implanting either Vitrasert or Retisert
Your Global Distributor of Adhesives, is a little like having a cataract operaSealants and Assembly Equipment tion,” says Ashton. The next step in the evolution of this series of implantable devices is called Electronic Assembly Iluvien. The device is much smaller & Protection than Retisert (only 3 millimeters long and 0.5 millimeter wide), but it’s Thermal Management designed to last about the same length Solutions of time. “It’s about the length of an UV Curing Systems eyelash and is small enough to fit into & Accessories a needle,” says Ashton. “This allows it to be injected directly into the eye in Dispensing Equipment an office visit [as opposed to outpatient & Surface Preparation surgery, with fewer complications]. The procedure is also far cheaper.” According to Ashton, future ophthalmic devices will continue to ellsworth.com/Assembly.html get smaller and more sophisticated. “Bioerodible systems are already in early stages of testing,” he points out. “Applying existing semiconductor [manufacturing processes] and nanotechnology [will create] ‘intelligent’ devices that respond ISO 9001:2000 to a disease or tell a physician if they are Visit our website and chat with the Glue DoctorTM about an adhesive assembly solution. about to run out [of a drug].” In addition to improved lens implants www.ellsworth.com 877-262-6029 and drug-device hybrids, another new device that intrigues many ophthalmologists is the artificial retina. “This device has given hope to patients asb08094ells.indd who 1 7/14/09 have lost vision from disabling retinal diseases such as macular degeneration,” says Shatz. “While the resolution is currently only able to allow for ambulatory vision, higher resolution electrode arrays under development will be able to differentiate letters and objects.” The artificial retina, called Argus II, is being developed by engineers at Oak Ridge National Laboratory (Oak Ridge, Micro-Percussion Scribing Laser Marking TN) and the University of Southern California (Los Angeles). It consists of an array of 60 electrodes that are attached to the retina. The electrodes Contact us for in-plant conduct information acquired from an analysis and demos. external camera to the retina to provide a rudimentary form of sight. The device has already been implanted in Tag Marking 2D Coding six patients. A newer, higher resolution & Reading model will be available within the next few years. A 800-394-9101
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www.assemblymag.com August 2009 / ASSE M B LY 29
ASSEMBLY
Parts Marking
When All You Need Is a Dot Marking parts with colored inks or stains is a fast, easy way to differentiate between similar-looking components, indicate pass-fail status or confirm that a specific process has been performed.
Parts such as calibration screws can be marked with stains that only become visible under ultraviolet light to indicate whether they have been tampered with. Photo courtesy ITW DYKEM
By John Keating Business Unit Manager, ITW DYKEM Olathe, KS and Claude Bergeron Product Line Manager, EFD Inc. East Providence, RI
M
anufacturers mark parts for many reasons: to differentiate between similar-looking parts; to indicate that a process has been performed or a quality check has been passed; to facilitate assembly; or to link a product or component to the assembly line or machine on which it was produced. Parts like calibration screws may even be marked with stains that only become visible under ultraviolet light to indicate whether they have been tampered with. One of the most common uses of color marking is to make it easier to tell the difference between parts that look similar. Although such parts may be marked with numbers, letters or some other i d e n t i fi e r, s o m e companies choose to color-code them as well, to speed and simplify identification on the shop floor. For example, two springs may appear identical, but may function very differently. Marking each one with a different color stripe is a simple way to tell them apart. Another major use for parts marking systems is in quality control. Parts are often marked after a test has been performed to indicate whether they have passed or failed. Parts are also marked to indicate that a particular process
30 ASSEMBLY / August 2009 www.assemblymag.com
has been completed. This is especially useful if that process does not visibly change the parts. Marking systems are often integrated into testing or production fixtures. An example is a flywheel that gets mounted on an engine with multiple bolts, which are then simultaneously tightened. When all of the bolts have been torqued to specification, the marking device moves into position and applies a dot to confirm that the operation was performed correctly. If the dot is not there, operators downstream will immediately know that additional inspection or corrective action is required.
Clogging can be minimized by using a low-volume, lowpressure spray system. Parts are also frequently marked with color to facilitate assembly processes. For example, assemblers may put a dot of stain on brake calipers to confirm that pads have been installed before mounting rims and tires. Or, a shaft could be marked to indicate which end to insert. Marking is also used in automotive and other stamping processes to check the contours of stamped parts during setup to indicate whether a bend has the correct radius or a crease is straight. In applications like this, color marking provides an easy way to point out any
discrepancies so the operator can fine-tune the press setup. Three Marking Methods Common part marking methods include handheld valve-actuated markers, contact marking systems that press a stain-saturated pad against the part, and noncontact spray marking systems. The simplest of all marking “systems” are handheld valveactuated markers, which are often used in processes such as filling an automatic transmission with fluid and then marking the dipstick for visual confirmation. Contact marking systems consist of an ink or stain reservoir fitted with a pad or dauber and mounted on an air cylinder or similar device. As the part moves into position or the test or process is completed, the actuator advances to press the saturated dauber against the part. Depending on the marking fluid, the parts may need to be clean and dry to achieve an acceptable mark. Noncontact marking systems typically use a pneumatic spray valve to apply spots, stripes and bands, with stain supplied from a tank or disposable reservoir. Depending on the application, the valve can be mounted in a fixed location or attached to an actuator that moves it to the part. In some processes, the part is rotated while the valve applies a band of color around the outer circumference. Pigment and Maintenance Marking fluids are commonly referred to as inks, staining colors or paints, and generally fall into one of two classifications: transparent or opaque. Transparent staining colors have a thinner viscosity than opaque stains and dry slightly faster. They are typically used on lighter colored substrates or in
marking applications involving tight tolerances, such as engine rods. Transparent stains will not settle or separate. Opaque stains use more pigment to produce a heavier mark, and perform well on both light and dark substrates. These stains apply slightly thicker than transparent stains and take slightly longer to dry. Thickness can be adjusted by adding thinner. Because they contain more pigment, opaque stains will settle over time, and daubers will need to be periodically agitated to work properly. Opaque stains also increase the likelihood of spray nozzles clogging and requiring maintenance. Nozzle clogging is a common problem with spray valves, particularly when using heavily pigmented, opaque paints and stains. To avoid applying a thick, heavy spray mark that is slow to dry, valve stroke is usually shortened to “choke down” the aperture to reduce coating thickness. This causes the pigment to be filtered out of suspension at the valve nozzle, causing it to clog. Clogging can be minimized by using a low-volume, lowpressure (LVLP) spray system to apply the stain. Because LVLP designs work with lower pressures and flow rates than standard spray systems, a longer valve stroke can be used. This leaves more space around the valve needle, which reduces the possibility of pigment building up to the point where it eventually blocks the valve nozzle. Separation is another issue with many pigmented stains. This occurs when the pigment separates from the carrier and settles to the bottom of the reservoir, resulting in fainter, less consistent marks that may not be picked up by visual scanning systems.
This spray valve has a dual-ported fluid head. A programmable air delay after each shot keeps the nozzle clean and reduces clogging and maintenance. Photo courtesy EFD Inc.
This spray marking system uses a motorized gear pump to keep pigmented inks in suspension and constantly circulating through the valve. Illustration courtesy EFD Inc. www.assemblymag.com August 2009 / ASSE M B LY 31
Parts Marking spray marking system is an example of this type of equipment. A motor-driven gear pump pulls fluid from the reservoir and supplies it to the spray valve, where it enters one side of the fluid head and exits the other. As fluid is returned to the reservoir, it produces a slight agitation that keeps the pigment from settling at the bottom of the tank. Because as little as 1 psi is sufficient pressure to keep the marking fluid constantly recirculating, a long valve stroke can be used to maintain open space around the valve needle, while a programmable air delay after each shot keeps the nozzle clean and further reduces the risk of clogging.
A simple dot of color can differentiate between similar-looking parts; indicate that a quality check has been passed; or link a product to the assembly line or machine on which it was produced. Photo courtesy ITW DYKEM
Both issues—clogging and separation—can be prevented with an LVLP spray marking system with a double-ported fluid head and
a recirculating pump that keeps the marking fluid moving so the pigment remains in suspension. EFD’s new 781RC recirculating
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Choosing a Marking System When comparing contact and noncontact marking systems, engineers should consider these factors: 䡵 marking speed. 䡵 the cost of the marking fluid and need to maintain inventory (individual stain bottles and applicators vs. less expensive bulk bottles). 䡵 the need to regularly monitor the system to ensure ink is in the bottle vs. using a tank that can be filled once at the start of a shift. 䡵 time needed to change ink bottles or refill a tank and whether the line must be shut down to do this. 䡵 time and cost of replacing contaminated or dried out pads and daubers. Once maintenance requirements, downtime, fluid costs and line speeds have been considered, a noncontact spray marking system often proves to be a more economical long-term choice. 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 parts marking, visit www.assemblymag.com to read these articles: 䡲 On Your Mark. 䡲 Rubber Stamping Assembly. 䡲 The Expanded Reach of Laser Marking.
Assemble it faster, better, for less. Find cost saving new products, technologies, and ideas at ATExpo.
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ASSEMBLY
Electronics Assembly
Riding the Mini Wave Automated selective soldering technology saves EMS facilities time and money.
Molten solder is pumped through this small nozzle to create a fountain with a directional or spherical shape.
By Reed Gaither CEO RPS Automation LLC Spokane Valley, WA [email protected]
S
elective soldering with a miniature wave or fountain of molten solder offers many advantages compared with conventional wave soldering equipment. It requires less energy, generates less dross, provides more control, and can reach certain joints that would otherwise be inaccessible. Moreover, there’s no need for custom-made pallets or shielding for the boards. These systems can be equipped with a single circular nozzle 2 to 20 millimeters in diameter, a rectangular nozzle 4 to 8 inches long, or multiple nozzles for soldering more than one joint simultaneously. Molten solder is pumped through the nozzle to create a fountain with a directional or spherical shape. In some systems, the printed circuit board is held stationary, and the solder fountain moves beneath it to solder pins, rows and connectors. The fountain travels in three axes (X, Y and Z) up to solder points and down and around bottom-side components. Precise motion control and the small size of the wave prevent damage to nearby components and pads. Other systems hold the fountain stationary and move the PCB. Often referred to as “top-side gantry” systems, these machines can position boards
34 ASSEMBLY / August 2009 www.assemblymag.com
along two additional axes of motion: tilt and rotation. These fourth and fifth axes enable the solder wave to get around bottomside components and penetrate areas that otherwise could not be reached by a three-axis system. In addition, top-side gantry systems can tilt boards for angled soldering, which can improve yields. Different Strokes: EMS Views Change is a constant in electronics assembly. New alloys, fluxes and temperature demands are the norm. Production volumes increase and decrease quickly, and design life
“We have decreased the cost of labor by at least half.”—Todd King, E.I. Microcircuits cycles can be short. Floor space is at a premium, and there is a constant push to reduce costs, increase productivity and improve quality. In this environment, assemblers must run lean, green and mean. This has opened up opportunities for selective soldering technology. Dave Sackett is a consulting engineer in Maplewood, MN, who has worked with many electronics assemblers. He recommends selective soldering systems driven by precision servomotors, as opposed to inexpensive stepper motors. Automatic loading is also a good feature.
“Handling of PCBs should be tool-free when possible,” he says. “Some systems use expensive and time-consuming tooling for different sizes of PCBs. [This] can substantially reduce the usefulness of the system as an economical and high-mix production tool.” Programmability is particularly important for any machine in a high-mix assembly environment. “Software should provide a simple user interface and utilize scanned images or Gerber data,” Sackett says. “It should only take minutes to select solder points and nozzle configurations. A simple jog-toteach set-up camera could also be used to program a board,” he says. For high-mix production, the system should be able to store an unlimited array of soldering programs. To save time and prevent errors, programs can be triggered automatically through a bar code reader. Filling a Gap In the past, high-mix, lowvolume assemblers had two choices for assembling mixed-technology boards: wave soldering or manual soldering. “Our first choice was always wave soldering,” recalls Todd King, vice president of operations at E.I. Microcircuits Inc. in Mankato, MN. “It is the highest volume and the most economical. What prevents wave soldering are unique components and some tight configurations particularly in [radio frequency applications], or large components that cannot be waved or masked. Then we [reverted] to hand soldering.” With production runs between 500 and 10,000 pieces, manual soldering is costly, not only in terms of labor, but also in quality control. Two years ago, the company invested in its first selective soldering system. Today, it has three in-line machines running both lead-free and standard boards. E.I. Microcircuits assembles many boards that require significant
masking or large copper ground planes, which are difficult to solder manually. Selective soldering with a mini wave provides constant heat like traditional wave soldering equipment, but with less waste. “We expect volumes to increase in these applications,” King says. “[These boards] will go directly to selective soldering, bypassing wave or hand soldering entirely.” In the past, E.I. Microcircuits would sometimes run mixedtechnology assemblies through a wave soldering machine and then another soldering operation for difficult through-hole components. Now, these assemblies go directly to the selective soldering system. “It can get in-between deep, tight parts and navigate around large components with consistent repeatability,” says King. “You simply can’t get that manually, regardless of how adept the operators might be. ...We have decreased the cost of labor by at least half [using selective soldering],” he says. Replacing Wave When Ayrshire Electronics first began looking at selective soldering technology, it had some concerns. James Beard, director of manufacturing for Ayrshire’s Oakdale, MN, facility, says the first machines he looked at were not flexible or easy to program. “Everything was customized,” he recalls. “You designed the board, and then you had the selective soldering [machine] designed around it. If you needed fast changeover, too bad. Plus, the footprint of the machines was almost the size of a standard wave machine.” Being a high-mix assembler, Ayrshire needed flexibility. The company finally invested in a miniwave system that can easily switch from one program to another. “It’s not tied to one product line or niche,” Beard says. “It can do point-to-point when needed, or drag soldering and a mini wave for some larger areas if needed. The
Soldering nozzles come in various shapes and sizes to suit specific applications.
Programmability is particularly important for any machine in a high-mix assembly environment. Soldering software should provide a simple user interface and use scanned images or Gerber data.
www.assemblymag.com August 2009 / ASSE M B LY 35
Electronics Assembly
In some selective soldering systems, the board is held stationary, and the solder fountain moves beneath it. In others, the fountain remains stationary, and the board moves.
system is integrated in-line for complete automated assembly, and the best part is that the footprint is 3.5 feet by 4 feet.” After a short while, Ayrshire completely eliminated wave soldering on its assembly line. A standard wave soldering system produces a wave that is 18 to 24 inches wide, whereas most PCBs are much smaller. This means the machine is heating a lot of solder and producing a lot of dross unnecessarily, explains Beard.
With their smaller wave nozzles, selective soldering systems are much better suited for boards that are 4 inches wide. The system can accommodate boards that are more than 4 inches wide by moving them in a serpentine pattern over the wave. Soldering programs can be adjusted to optimize key parameters, such as speed, immersion depth, dwell time and temperature. The net result is that while the smaller wave nozzle solders
joints at a slightly slower rate than a traditional wave-soldering machine, it’s more efficient in the long run when maintenance, uptime, consumables and defect rates are factored in. “We specialize in low- to mediumvolume, high-mix, double-sided, surface-mount boards with maybe one or two through-hole parts on them,” says Beard. “Instead of using a wave solder [machine, which required] custom pallets or a masking step, our assemblies now go directly from the dispensing line to the selective soldering step and then on to various inspections.” Eliminating the wave soldering system saved Ayrshire approximately $120 per day in energy costs and eliminated some 3,500 pounds of dross. “The dross from selective soldering is only spoonfuls,” Beard says. Ayrshire also saved on labor. “When we went to selective soldering two and a half years ago, we had 16 people doing hand soldering during the first shift, eight people on the second shift, and four on the third,” Beard recalls. “Today, we are building the same volume and same mix of products, and we are down to six people on the day shift. That’s a manpower reduction of 75 percent.” Selective soldering has made a difference in defect rates, too, particularly with small boards for radio frequency applications. “[If there’s] a tiny icicle on a joint, all of a sudden you have an antenna and it throws off the whole board,” Beard says. “That’s where selective soldering really shines. It has cut our defects—bridging, damage to other parts, and so forth—down to virtually zero.” A For reprints of this article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.
ASSEMBLY ONLINE
Although the small nozzle solders joints at a slightly slower rate than a traditional wavesoldering machine, it’s more efficient in the long run when maintenance, consumables and defect rates are factored in. 36 ASSEMBLY / August 2009 www.assemblymag.com
For more information on soldering technology, visit www.assemblymag.com to read these articles: Three Boards in a Fountain. Soldering Soldiers. Step up to the Bar.
ASSEMBLY
ASSEMBLY EVENTS
Don’t Miss the Big Show Find the tools your company needs to succeed at ATExpo 2009.
As the economy makes its way out of the downturn, assemblers will need to work smarter and more efficiently than ever if they are to succeed in an increasingly competitive global marketplace.
By Adam Cort Senior Editor
D
espite the economic hard times, assemblers in the United States will still spend more than $2.5 billion on new assembly equipment this year, according to ASSEMBLY magazine’s 13th annual capital equipment spending report. Not only that, as the economy works its way out of the downturn, assemblers are going to have to work smarter and
more efficiently than ever if they are to succeed in an increasingly competitive global economy. To make sure your company has the capital equipment it needs to survive in this kind of environment, be sure and check out this year’s Assembly
Technology Expo (ATExpo), set for Sept. 22-24 at the Donald E. Stephens Convention Center in Rosemont, IL, immediately adjacent to Chicago’s O’Hare airport. As in 2008, ATExpo 2009, which is sponsored by ASSEMBLY magazine, will be co-located with the Medical Design & Manufacturing Midwest (MD&M Midwest) show and the Green Manufacturing Expo. Also co-located with this year’s ATExpo will be Quality Expo and the new Design & Manufacturing Midwest and Electronics Midwest shows. In addition, ATExpo 2009 will feature a range of conference sessions, including a quality track, a design track, a medical track, a green manufacturing track, and a track on automation and assembly. The latter, which is being sponsored and organized by ASSEMBLY magazine, will be comprised of a number of specialized sessions, including those on plastics assembly, affordable automation, lean manufacturing, compliant design, affordable robotics for smaller manufacturers, machine vision and recycling. (See sidebar, page 38.) Building the Future As it has been for more than a quarter century, ATExpo is the onestop source for assembly-related equipment and materials, including automated assembly systems, adhesive and solder dispensing machines, robots, conveyors, parts feeders, circuit board assembly equipment, adhesives and sealants, mechanical fasteners, machine
www.assemblymag.com August 2009 / ASSE M B LY 37
ASSEMBLY EVENTS
Prepare for the Rebound at the Assembly Conference As the economy gets back on its feet again, assemblers are going to have to work smarter and better than ever before to remain competitive. This, in turn, will require not only the latest technology, but new ways of thinking—both of which will be the focus of this year’s assembly conference at ATExpo. On Tuesday, Sept. 22, the conference kicks off with three tracks: “The Ultimate Plastics Assembly Seminar,” “Lean Manufacturing,” and “How to Profit from Automated Assembly.” The plastics assembly track will feature industry experts addressing everything from ultrasonic welding and light-cure adhesives, to the best ways of placing inserts and using the latest environmentally friendly materials. The track on lean manufacturing will include speakers such as Kevin Duggan, founder of The Institute for Operational Excellence, discussing how to employ lean techniques to grow a business in a recovering economy. The automation track will feature speakers such as Mikron Corp.’s Jim Mueller, who will explain how designing a new product with assembly in mind can reduce costs. On Wednesday, the conference continues with three more tracks: “Technology for Profitable Assembly,” “Robots and Vision,” and “Preparing for the Economic Recovery.” The session on profitable assembly will begin with presentations on resistance welding, crimp quality verification, and press fits and process monitoring. In the afternoon, the track continues with a panel discussion on how even small companies can benefit from robotics. There will also be a presentation by Denise Coogan, manager for safety and environmental compliance at Subaru of Indiana Automotive Inc., on how her plant has cut the amount of solid waste it generates to zero. The track on robots and vision will include sessions on robots and the “green” economy, collaborative robots working in close proximity to people, and how to employ machine vision to improve your bottom line. In the afternoon, Dr. John Kamauff, a
vision systems, power tools, presses, workstations, process monitoring systems, and test and inspection equipment. The show also plays host to dozens of integrators and machine builders with experience in assembling everything from the tiniest consumer gadgets to high-end medical devices and missioncritical components for the automotive and aerospace industries. This year’s ATExpo will include a number of what show organizer Canon Communications describes as technology-specific areas, including a sensors and vision area, a wire harness processing area and a new lean “factory,” which will feature lectures and a step-
principal and expert on supply chain management at Archstone Consulting, will give a pair of presentations titled “North America: the New Low Cost Manufacturer” and “Planning for the Rebound.” In these sessions, attendees will learn how companies can position themselves to take advantage of the latest trends in manufacturing. Finally, the conference will end on Thursday with a pair of workshops: “Reducing Part Counts and Product Costs Through Compliant Design” and “Lean Workshop: Operating System Design.” Chairing the session on complaint design will be Sridhar Kota, Ph.D., a professor of mechanical engineering at the University of Michigan. Leading the workshop on lean manufacturing will be Matt Zayko of the Lean Transformations Group. Individual sessions are about an hour long, and will begin at 9 a.m. and end at 3 p.m. on Tuesday and Wednesday. Thursday workshops will begin at 9 a.m. and finish at noon. For more information, including session abstracts and a complete conference schedule, go to www.devicelink.com/ expo/atexpo09/conference.html.
by-step demonstration on how to build an actual lean production area. Canon Communications is also creating an Innovation Briefs Theater, a 50-seat amphitheater complete with its own screen, where experts can give 30- to 40-minute seminars on various technologies. Co-Located Shows For those with responsibilities in the areas of design and planning, this year’s Design & Manufacturing Midwest show will include exhibitors featuring the latest in CAD, CAM and CAE software, computer hardware and peripherals, contract manufacturing services, linear motion devices, material handling
38 ASSEMBLY / August 2009 www.assemblymag.com
systems, plant engineering products, motors, drives and other manufacturing support equipment. Similarly, Electronics Midwest will be your one-stop source for the latest in component insertion and placement equipment, soldering machines and everything else you’ll need to manufacture and package printed circuit boards. For those either already a part of, or planning to become a part of the redhot medical-device industry, MD&M Midwest will bring together many of the major equipment, materials and service providers doing business in the Midwest and beyond. In fact, the five states comprising the
upper Midwest—Illinois, Wisconsin, Michigan, Indiana and Ohio—are already home to some 1,800 medical OEM facilities producing about $20 billion worth of medical devices and equipment every year. Thanks to the United States’ rapidly aging population and continuing advances in medical technology, those numbers will only get bigger in the coming years. Finally, for those looking to either become a part of the new green economy or cut their costs through environmentally friendly technologies, there is the Green Manufacturing Expo. Now in its second year, this event focuses on sustainable manufacturing and covers economically sound and nonpolluting manufacturing processes that conserve energy and natural resources. Products and services featured will include solar and wind power systems, recyclable and reusable packaging, energy management software, and consulting for energy management, recycling and waste treatment. Last but certainly not least, for those in search of the quickest possible return on investment for their trade show dollar, this year’s show will include an hourly “grab bag giveaway.” Every day of the show, between 10:30 a.m. and 3:30 p.m., there will be a drawing each hour, with prizes including MacBook Air laptops, Best Buy gift cards, iPhones, and iPod Nanos. Registration Information A single entry badge allows attendees to visit all six shows. If you preregister online or bring show material with you on-site, admission to the shows is free. Otherwise, you will be charged an expo-only fee of $55 to register on-site. Online registration is available even on show days. For more information, current exhibitor lists and to register for free show admission, visit any of the show web sites: www.atexpo.com, www. manufacturingweek.com, www. qualityexpo.com, www.mdmmidwest. com, www.greenmfgexpo.com and www.electronicsassemblyshow.com. A
Join Us at the Lean Factory!
Sponsored by the Lean Factory Group, comprised of Bosch Rexroth Corp., Orgatex Americas LLC, Leonardo Group Americas, and Omron STI, this year’s Lean Factory exhibit will demonstrate the importance of a data-driven approach to line design; the need to create an environment that supports lean with the right equipment
and infrastructure; and tools that can be used to create a visual factory. Attendees will see presentations on lean manufacturing; interact with experts in the field; and take part in the step-by-step creation of the perfect lean production environment, culminating in an actual build demonstration on an optimum lean line.
See us at ATExpo, Booth 1214 www.assemblymag.com August 2009 / ASSE M B LY 39
Products Grippers Certified for Clean Room Use Grippers are now certified for use in Class 5
Painting Robot Is Compact, Flexible The Paint Mate 200iA intelligent mini paint robot can be used to paint small parts and offers a cost-effective alternative in applications that would otherwise require multiple fixed paint guns. The system incorporates all the features of the popular LR Mate 200iC, including wrist load capacity, repeatability and speed. The robot is extremely flexible and can be mounted on the floor, on a tabletop, at an angle or inverted. FANUC Robotics America Inc. www.fanucrobotics.com 800-477-6268
Crimper Accommodates Multiple Stations clean rooms according to ISO 14644. Among the grippers now certified are PGN-plus parallel grippers, the DPG-plus sealed parallel gripper, the PZN-plus centric gripper, the DPZplus sealed centric gripper, the MPG miniature parallel gripper, the MPZ miniature centric gripper and the SRU rotary module. SCHUNK Inc. www.schunk.com 800-772-4865
The CrimpCenter 36 can accommodate up to six processing stations and is suitable for a use in a variety of applications employing cross sections from 24 to 12 AWG. Modern manufacturing materials and a number of new proprietary technologies allow for a compact, economic design without compromising quality. Proven state-of-the-art components provide outstanding output rates, while synchronized Ethernet powerlink ensures fast and continuous communication between software and servo drives. Schleuniger www.schleuniger-na.com 603-668-8117
Reactor H-VR Offers Adjustable Ratio Settings The Reactor H-VR is a simple-to-operate, variable-ratio dispensing system that can be
Test, Monitor System Easy to Configure The sigPOD PSV is an out-of-the-box, user configurable system that can be used to test or monitor virtually any operation during manufacturing, including press, torque, vibration, dispense and functional test. An easy-to-use setup interface allows operators to leverage an expansive library of processing and analysis tools. The system can be used on up to eight channels to allow for greater output without sacrificing quality. Sciemetric Instruments www.sciemetric.com 866-900-7054
Leak Detector Minimizes Operator Error used to process polyurethane foams and polyurea coatings. Designed for materials that have extreme differences in viscosity between their A and B components, the system allows end users to spray infinitely variable volumetric ratios ranging between 1:1 and 2.5:1. Maximum fluid output varies depending on the ratio setting. Graco Inc. www.graco.com 877-844-7226 40 ASSEMBLY / August 2009 www.assemblymag.com
MS-60Dry helium mass spectrometer leak detectors can be used to test the integrity of a wide variety of systems, containers and parts using helium as a tracer gas. The MS-60Dry is available with a standard 16 cfm Dry foreline-roughing pump for faster cycle times and use in clean room applications. The system’s software allows users to both locate and measure leaks with ease, at the same time minimizing operator error and maximizing throughput. VIC Leak Detection www.vicleakdetection.com 631-737-0900
Belt Conveyors Are Sturdier, Easy to Service
polyethylene. The fasteners are intended for one-time use and provide a cost effective means of creating a lightweight assembly. One size pin fits all lengths of posts. Posts are available in lengths from 1/2 inch to 1 1/4 inches. Micro Plastics Inc. www.microplastics.com 800-466-1467
TB belt conveyors feature sturdy aluminum covers to protect their chains and pinions. In
lower assembly costs. The adhesive is bright blue in its uncured state making it easy to see on the surface of substrates, in deep wells or when sandwiched between two layers of material. DYMAX Corp. www.dymax.com 877-396-2963 addition to providing superior protection, the covers make the conveyors easier to service because they require fewer locking screws. The conveyors are available in six different frame widths, from 60 to 250 millimeters, and can be ordered with either a single or double belt. The drive unit can be installed horizontally or vertically at any point along the entire length of the frame. Montech www.montech.com
System Handles Sensitive Materials The Dos A300 dispenser can be used to process everything from liquid, self-leveling
Microscope Records High-Speed Motion The VW-6000 motion analysis microscope is the world’s first microscope with high-speed magnified video-capture capabilities. The system can record up to 24,000 frames per second,
Robot Has ‘Zero’ Footprint
materials to abrasive resins. It is especially well suited to handling liquid and mediumviscosity polyurethanes, silicones and epoxies with or without filling materials. It can also be used for dispensing humidity-sensitive materials that need to be processed under vacuum. The system can be configured as a stand-alone manual workstation or as part of a larger production line. Scheugenpflug www.scheugenpflug.de
The new overhead-mounted RS3 SCARA robot is literally a “zero footprint” robot, saving assemblers valuable floor space. The system can be easily integrated into a compact assembly cell and offers 450 degrees of axis rotation for omni directional access. It comes standard with the low-cost, high-performance
making it possible to film moving targets that cannot be otherwise captured. Because it is small and portable, the system can be used on the factory floor as well as in the lab. Keyence Corp. of America www.keyence.com/vw
Mobile Workstation Safeguards Laptops This mobile laptop computer workstation provides a secure place to both store and use a laptop, at the same time positioning it at a com-
Posts, Pins Facilitate Light Assembly Micro PowerDrive RC180 controller to facilitate ease of use and reliability. EPSON Robots www.robots.epson.com 562-290-5910
New post-and-pin combination includes pins molded in white polycarbonate material and posts in various lengths molded in white
Adhesive Turns from Blue to Clear The 3-20794 See-Cure adhesive is a colorchanging material formulated with Ultra-Red fluorescing technology. It bonds to a variety of plastics and cures clear in less than a second when exposed to high-intensity UV light, enabling faster processing, greater output and
fortable work height. The station’s four largediameter swivel casters ensure easy rolling and maneuverability. The casters can be locked for greater safety and stability while working. The www.assemblymag.com August 2009 / ASSE M B LY 41
Products station provides a workspace that is 42 inches wide, 26 inches deep and 38 inches high. Custom dimensions are also available. Creform Corp. www.creform.com 800-839-8823
kit includes all necessary mounting hardware, making installation as simple as tightening down the bolts. GAM www.gamweb.com 888-GAM-7117
Slides Available in Five Days
Rails Provide Accuracy, Cost Savings
Customized LSK linear slide kits are now available in just five days, dramatically cutting lead times and reducing the overall cost of system assembly. The kits are compatible with any linear slide, belt or ball screw actuator, and any motor or gearbox. Standardized components are available for those applications requiring extra stiffness or dampening. Each
Sensors Combine Accuracy, Value The OD Value line of optical displacement sensors provides high-accuracy performance at a competitive price with a variety of interface capabilities for use in a wide range of
LFS 12 Series low-profile linear rails and car-
riages can be used in those applications that require low cost and accuracy, such as door enclosures and transfer systems. Each linear rail and carriage set employs a set of mating V-groove rollers. The standard rail length is 3 meters, but custom lengths are available. Techno Inc. www.technoautomation.com 800-819-3366
268 METRIC HINGES for a cleaner environment
quality control applications in the automotive, robotics and electronics-semiconductor industries. The sensors can measure targets regardless of color or reflectivity and include an easy-to-read bar graph display for fast installation and maintenance. SICK www.sickusa.com
Leak, Mass Flow and Electrical Testers starting at $2990.00
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Dispense, Spray System Includes Tilt Feature
Pipette Enables Contaminate-Free Dispensing
The Precisioncoat spray and dispense system now includes a programmable tilt and rotate feature, needle calibration and a vision system to help customers achieve maximum efficiency, flexibility and accuracy as they spray
The Stepper pipette enables contaminate-free dispensing in a simple-to-operate, handheld system. The dispenser incorporates a lightweight, ergonomic design and is constructed of aluminum for maximum durability. Users
three sizes and offers positive displacement dispensing in a range of volumes from 0.01 to 1.00 milliliter. Each pipette can dispense up to 100 shots per fill. Tridak www.tridak.com 860-626-6700
Readers Fill Multiple Niches HS-1 and HS-2D handheld readers provide out-of-box, plug-and-play performance and
and dispense coatings onto printed circuit assemblies and other devices and substrates. The programmable tilt and rotate feature, in particular, allows users the flexibility of five separate axes to coat alongside and underneath a wide variety of components. Specialty Coating Systems www.scscoatings.com
can dispense a variety of low- to mediumviscosity materials. The pipette is available in
can be plugged into a number of standard Microsoft Office programs, including Word and Excel. The HS-1 is lower-cost reader for use with linear barcodes, such as those found on printed black-and-white labels. The HS-2D reader is a higher performance model that can
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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.
Specializing in packaging adhesives and encapsulants in convenient syringe and cartridge systems, ideal of Electronic assembly. • Premixed and frozen two component • Difficult to package one component resins • Air-free syringes and cartridges for automated X-Y-Z dispensing systems • Maximum 5-day lead time from receipt of materials • Custom mixing and blending per your specifications
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5/6/09 10:14:19 AM Asb08094kit.indd 1
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Products be used to decode both linear barcodes and 2D symbols in a wide range of environments, including clean rooms. Microscan www.microscan.com
insulation residue as it is removed from the wires during stripping. Eraser Inc. www.eraser.com 315-454-3237
Wire Stripper Collects Insulation Residue
Robotic Cleaner Handles Heavier Loads
The Model DV1 twin-wheel wire stripper with integral dust collector can be used to strip magnet, enamel and film-insulated wires, as well as round, rectangular and square section wires with insulations such as Formvar, ML, Dayglass, Isonel and Polythermaleze. The system’s integral dust collection traps
Ecoclean flexible robotic cleaners can now accommodate industrial parts weighing up to
in the automotive and commercial vehicle industries. Dürr Ecoclean www.durr-ecoclean.com
TFT Systems Available with Hollow Shafts Torque Functional Test (TFT) systems providing monitored and measured amounts of torque during assembly and test operations are now available in a hollow shaft configuration. The new feature allows operators to access components with tools or sensors inserted through the center hole at the same time the
300 kilograms, thanks to a new conveyor component that reorients the parts being cleaned via a tilting station, thereby allowing the robot to handle heavier parts than in the past. The system is especially well suited to cleaning parts with complex geometries, like those
ELECTR C! • Electric Sheet Metal Handling & Work Holding • Fastt Delivery
VLB-900M Mini Locking Bit Comes With the Most Reliable Screwfeeding System on the Market. PLKE & PLCE E
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44 ASSEMBLY / August 2009 www.assemblymag.com
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components are being processed. The TFTs employ servomotors, precision position sensing feedback technology and extremely accurate torque transducers to produce controlled torque inputs and feedback monitoring. Promess Inc. www.promessinc.com 810-229-9334
Tubing Good for Appliances, Food Industry Ethelplas tubing is extruded from nontoxic, 100 percent virgin linear low-density Polyethylene resin for use in commercial and household appliances, the food industry and laboratory testing equipment. It provides good resistance to chemicals and is nonconductive. The tubing is available in nine different sizes, ranging from a 1/16-inch inner diameter to a 5/8-inch inner diameter. Ark-Plas Products Inc. www.ark-plas.com 870-453-2343
resistant to motor oils, transmission fluids and most other workrelated compounds, such as greases and cutting fluids. The stains can be applied by brushing, spraying or dipping. Dry time is less than 15 minutes. ITW www.dymon.com 800-443-9536
Laser Scanner Is Precise, Portable The SLP-500 3D laser scanning probe is a high-precision probe delivering virtually noise-free scan data for use in the automotive and aerospace industries. The system provides a laser line length of 50 millimeters and scans at very high speeds, making it ideal for use in scanning mid- to largesized objects, such as molds, stampings and sheet metal. The probes are portable and can be easily integrated with a coordinate measuring machine (CMM) arm. Laser Design Inc. www.laserdesign.com 952-884-9648
Applications include: small linear slides, medical equipment, instrumentation, packaging, material handling, rotary actuators and more
• High Energy Capacity in Minimum Sized Packages • Proven Designs & Performance • Ideal for Mounting in Confined Spaces • Self-Compensating & Adjustable Models
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Stains Are Environmentally Friendly
Farmington Hills, MI 48335 tel: 800-521-3320 fax: 248-476-2470 e-mail: [email protected]
DYKEM water-based stains can be used to permanently color code springs, small parts, tools and finished assemblies. The stains produce little odor and emit few VOC’s. Their non-xylene based formulation is
acecontrols.com
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www.assemblymag.com August 2009 / ASSE M B LY 45
Products Clamps Combine Accuracy, Ease of Use
wafer without leaving a mark, even when handling wafers that are smaller than the contact surface of the gripper. The gripper can also be safely used in a clean room environment. Schmalz Inc. www.vacuworld.comasb0809
Zero Point clamps offer ease of alignment, high-accuracy positioning and high clamping forces. They can be used with either hydraulic
or pneumatic actuation. Each clamp employs a series of balls that roll freely in a form-fitting ball channel that allows them to easily reposition themselves, allowing heavy fixtures to self-align easily. All components are made of stainless steel. Jergens Inc. www.jergensinc.com 800-537-4367
height, 5-inch-diameter casters and a choice of hanging drawers are also available. The benches come in light gray, bright blue or sand. Lista International Corp. www.listaintl.com 800-722-3020
Gantries Provide Speed, Precision AGS15000 series Cartesian gantries incorporate a planar design that minimizes dynamic pitch errors for use in a wide range of precision applications, including stencil cutting, fuel
Gripper Configured for Solar Production The new SWG vacuum gripper is configured for precise, gentle handling of highly sensitive wafers and solar cells. It provides a cycle time of 1 second and grips the entire surface of the cell manufacture, high-speed pick-and-place systems, automated assembly, dispensing and high-accuracy inspection. The system’s BLM and BLMH series brushless linear servomotors provide speeds of up to 3 mps and 5G acceleration. Aerotech www.aerotech.com 412-963-7470
Workbenches Are Sturdy, Economical The Arlink 7000 workbench is a cost-effective, easily assembled, general-purpose workbench capable of supporting up to 1,000 pounds. It is available with a range of work surfaces, including plastic laminate, static dissipative laminate and butcher block. Leg extenders for extra
Classified Need Work Benches
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For information on Classified Advertising call Vito Laudati: 630-694-4018 46 ASSEMBLY / August 2009 www.assemblymag.com
Advertisers Index Ace Controls ....................................................... 45
Promess ............................................................. IFC
AMSP All Metric Small Parts .......................... 42
Quality Bearings & Components .................... 12
Assembly Technology Expo 2009.................. 33
Robotic Industries Association ....................... 11
ATEQ .................................................................... 42
Saejong Industries ............................................. 43
Cincinnati Test Systems ................................... 27
Sankyo .................................................................. 24
Conductix-Wampfler.......................................... 32
Schleuniger Inc. .................................................. 10
DEPRAG Inc. ....................................................IBC
Schmidt Technology .............................................5
Dymax ................................................................... 25
Schunk Inc. .............................................................3
Edgewater Automation ..................................... 13
Sciemetric ...............................................................7
EFD ..........................................................................1
Sealant Equipment & Engineering ................. 39
Ellsworth Adhesives ...................................29, 43
Technifor ............................................................... 29
I & J Fisnar Inc. ...................................................BC
Techno .................................................................. 21
Janome Industrial Equipment USA Inc.......... 45
Techno Sommer ................................................. 12
Lista International Corp. ................................... 15
Turck ...................................................................... 28
PHD Inc................................................................ 44
Visumatic Industrial Products Inc. .................. 44
ProLine ....................................................................4
Weiss North America ........................................ 26
This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.
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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 9 (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 August 2009 / ASSE M B LY 47
Leading Lean Jamie Flinchbaugh Partner The Lean Learning Center Novi, MI
Close the Knowledge Gap
I
n the past two columns, I have used the A3 improvement process to explore some of the subtler but broad skill sets and mindsets of lean. A3 can be a helpful method to guide your thinking, and it enables greater collaboration and coaching. Last month, I focused on the imperative of good problem statements and the thinking that goes into them. This month, I move to the next quadrant of the A3, defining and clarifying the current condition. This section of an A3 can be populated with data, stories, pictures and anything else that helps explain the current condition. It should explain why you are getting the results that you are getting and where you must focus to make the required changes. But there is more to this section than simply cutting and pasting your favorite Excel chart. The underlying function of this quadrant is to drive learning and knowledge. Lean businesses constantly focus on generating new knowledge about how their processes and organizations really work. In this part of the A3 process, you should focus on that purpose. There are two fundamental questions that help in this process. The first is, what do I need to learn more about? Another way to phrase it would be, what specifically do I not understand in the areas where I need to gain knowledge? There’s no need to gather “new” knowledge about something you already
understand. The assumption is that there is something you don’t quite understand, so focus on exactly what that might be. This requires humility and curiosity. You must be willing to use what I consider one of the more powerful phrases a leader can use, “I don’t know.” And you must have the curiosity to invest time and energy in pursuit of that knowledge.
Close knowledge gaps before closing performance gaps.
48 ASSEMBLY / August 2009 www.assemblymag.com
The second fundamental question is, by what method can I learn this knowledge? There are many methods you may deploy. I have written more than once about the power of direct observation. Whenever you have to suspend your assumptions and trim your filters, you are more open to what is really going on. Going directly to the point of activity, whatever and wherever that is, can greatly expand your knowledge. There are other methods. You should deploy the simplest approach to gain the knowledge you need. The “5 Why” problem-solving method is a good example. In the “5 Why” method, you keep asking “why” about a condition until you get to the root cause. Invariably, you’ll hit the root cause by the
fifth time you ask “why.” The intent is not documentation or ensuring a particular rigor. It is a knowledge discovery process. That, I believe, is it’s real value. Developing and testing a hypothesis is also a good way to generate knowledge. Why bother? The fact is, you must close your knowledge gaps before you can close your performance gaps. Closing performance gaps where the knowledge is already clear and available is often simply a matter of execution. If you only need to execute what you already know, then the A3 won’t help you. The thinking process enables you to close performance gaps that are more challenging. To close those gaps, new knowledge, insight and maybe even wisdom are required. If you try to close the performance gap before you close the knowledge gap, you will ultimately end up back where you started. The second quadrant of the A3 is meant to capture the current condition. The ability to do this is found in those two key questions. What do I need to learn more about? And, how can I learn it? Keep these two questions in mind, and you will move forward with a high probability of success.
Email Jamie with comments via [email protected]. For his recommended books see tinyurl.com/leadinglean
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Auto Supplier Rides Winds of Change pg 14
Ophthalmic Assembly 22 Marking Dots, Stripes 30 Selective Soldering
34
ATExpo Preview
37
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August 2009
Vol. 52, No. 9
22
ASSEMBLY 66
COVER STORY
30
14 Automotive Supplier Rides Winds of Change 䡵
When a Nevada startup went looking for a manufacturer to assemble a new type of wind turbine, automotive supplier MasTech Manufacturing leapt at the opportunity.—John Sprovieri
34
FEATURES
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䡵 22 Better One or Better Two?
Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ophthalmic device manufacturers keep an eye on new technology.—Austin Weber
䡵 30 When All You Need Is a Dot
Marking parts with colored inks or stains is a fast, easy way to differentiate between similar-looking components, indicate pass-fail status or confirm that a specific process has been performed.—John Keating and Claude Bergeron
34 Riding the Mini Wave 䡵
Automated selective soldering technology saves EMS facilities time and money.—Reed Gaither
37 Don’t Miss the Big Show 䡵
Find the tools your company needs to succeed at ATExpo 2009.—Adam Cort
Time to back health care reform.—John Sprovieri
Automation Profiles . . . . . . . . . . . . . . . . . . 8 System handles fragile components.—John Sprovieri
Quality in Assembly . . . . . . . . . . . . . . . . . . 9 Software helps assemblers manage quality tasks. —John Sprovieri
We Fed It . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 System feeds, assembles springs.—John Sprovieri
New & Noteworthy . . . . . . . . . . . . . . . . . . 12 All-purpose gloves made from bamboo.
Assembly Lines . . . . . . . . . . . . . . . . . . . . . 16 Group launches wind energy data base.
Assembly in Action . . . . . . . . . . . . . . . . . . 18 Single-cable camera maximizes efficiency.
Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Classified . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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Cover photo courtesy Mariah Power
2 ASSEMBLY / August 2009 www.assemblymag.com
Automating Battery Assembly Robot Guidance Assembling With Lockbolts Assemblers Get a Lift
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The ‘Holy Grail’ of Ophthalmic Devices Engineers are developing an artificial retina that includes 60 implanted electrodes to help patients with impaired vision.
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Editorial
ASSEMBLY
Time for Health Care Reform
R
ecently, while cutting some fruit for breakfast, I nearly sliced off the tip of my left index finger. After much bleeding, abundant foul language, and a trip to the emergency room, I’m happy to report the finger was saved. Including a tetanus shot and skin glue, the bill for my mishap totaled an astounding $982. I shudder to think of the bill had I been in a serious accident. Thankfully, I have health insurance, but how long will that continue when treatment for a simple cut costs nearly $1,000? Almost all U.S. manufacturers offer health benefits to their employees, but the rising cost of those benefits is impairing their ability to hire workers, battle overseas competitors, develop new products, and invest in assembly technology. Employer-sponsored health insurance premiums have nearly doubled since 2000, a rate three times faster than wages. In 2008, the average premium for a family plan purchased through an employer was $12,680, which is nearly the annual earnings of a full-time minimum wage job. According to a 2008 survey conducted by the National Association of Manufacturers, 55 percent of small and midsized manufacturers reported that their health care costs increased by more than 10 percent during the past year. The 2008 election seems finally to have goaded Congress to action. In July, the House and Senate released draft reform bills. The bills are too big to be elaborated here, but here are a few key provisions. People who get insurance through their employer would retain that coverage. A new Health Insurance Exchange would be created so small employers and uninsured individuals could comparison shop among private and public insurers. Over time, the exchange would be opened up to all employers as another choice for covering their employees. Premium subsidies would be provided to individuals and families with low and moderate incomes. The measure is expected to cost $1 trillion over 10 years, a sobering number to be sure. It will be paid for with a mix of tax hikes and spending cuts on programs like Medicare. The House plan would apply an income tax surcharge on the wealthiest Americans. Another possibility is to limit the tax exemption on the most expensive health benefits plans from employers. Just as there can be no one solution to our increasing energy demands, health care reform must take a multipronged approach to the myriad factors that drive up costs. That means legislators on both sides of the aisle must swallow some bitter medicine. Sorry, Democrats, tort reform must be part of the health care bill. Too bad, Republicans, but a public option should be included in the insurance exchange. Whatever bill emerges from Congress—and we must demand a legitimate proposal this year—manufacturers should get behind it. The worst we can do is nothing.
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TOM ESPOSITO Publisher [email protected] BILL DEYOE Associate Publisher [email protected] JOHN SPROVIERI Editor [email protected] AUSTIN WEBER Senior Editor [email protected] ADAM CORT Senior Editor [email protected] DONALD E. HEGLAND Editorial Director Emeritus 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 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 Michele Weston-Rowe Directories Nikki Smith Human Resources Marlene J. Witthoft Conferences & Events Scott Wolters Clear Seas Research John Thomas
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Automation Profiles
System Handles Fragile Components The glass ampoule is only 0.004 inch thick and very fragile.
When designing this system to assemble an adhesive applicator, engineers knew that glass and adhesive can and will get everywhere that they do not expect it.
H
andling glass can be challenging for any automation project. Actuators and grippers have no appreciation for the delicacy of an object. Glass parts in the wrong place at the wrong time are no match for hardened steel. Allied Automation has designed several systems that process thin glass containers safely and efficiently at high speeds. So when a medical manufacturer approached Allied to build a system to assemble an adhesive applicator, the company knew how to get the job done. Besides the adhesive itself, the applicator consists of a plastic swab tube, a glass ampoule and a plastic filter tip. A solvent bonds the filter to the tube. The ampoule is only 0.004 inch thick and very fragile. In this profile, Allied’s president, Jeff Graham, and engineering manager, Nathan Marshall, describe how the machine works. For more information, visit www.alliedautomation.com or call 919-362-4440. Describe the system. The machine has two components: an eight-station rotary dial and a recirculating puck conveyor. The dial is equipped with removable nests that hold four parts each. Each puck carries eight parts, and the conveyor accommodates 800 parts. The first station places four tubes in a nest and inspects for them presence and height. The second station lifts the tubes, supports them from the inside, and punches vent holes, depending on the product. (A product variant does not require vent holes.) The third station gently places the ampoules into each tube. Tooling at this station confirms the presence, length and integrity
8 ASSEMBLY / August 2009 www.assemblymag.com
of the glass. At station four, the filters are pressed into the tubes to complete the assembly and retain the ampoule. The fifth position was intentionally left free of tooling to facilitate access to the machine for cleaning and maintenance—an often-overlooked part of sound machine design. The sixth position inspects and records the assembled height of the product. This is done with linear variable displacement transducers. At station seven, good assemblies are off-loaded to the conveyor, where the solvent is applied and cured. The solvent is dispensed with a resolution of ±0.1 microliter. Bad assemblies are indexed to station eight, where they are deposited in a bin. What are the dimensions of the assembly? The machine handles two different product sizes. One is 52 millimeters long; the other is 72 millimeters long. Both are 8 millimeters in diameter. What equipment feeds the parts? Vibratory bowls with bulk hoppers feed the tubes and filters. The ampoules are fed manually. We also had to develop innovative ways to deal with the static electricity generated when feeding thin plastic parts. What inspections are included? All parts of the assembly are inspected for presence, orientation and assembled height. Inspections are performed with photoelectric sensors, capacitive proximity sensors and linear encoder-based contact probes. Additional sensors monitor the level and displacement of solvent, as well as the correct position of every actuator on the machine during operation. What is the production rate? 4,200 parts per hour. Only two people operate the entire system. Can the system accommodate variants? The system handles two different product sizes both with and without vent holes. Changeover is fully automatic. The product to be assembled is selected through the touch-screen, and all machine adjustments are made automatically. What was the most challenging aspect of building the system? The system must handle an ampoule every second without breaking any, and it must be easily accessible for cleanup when ampoules do break. It was critical to the success of the project that we understood that glass and adhesive can and will get everywhere that you do not expect it. We used chemical- and corrosion-resistant materials throughout the machine. The system is enclosed with tempered safety glass, so the windows stay clear even after cleaning with aggressive chemicals. All pneumatic actuators are equipped with corrosion-resistant rods. The system also had to comply with FDA requirements and clean-room specifications. A 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 sprovierij@bnpmedia. com, or call 630-694-4012.
Q
UALITY in ASSEMBLY
Software Helps Assemblers Manage Quality Tasks
I
n these days of far-flung supply chains and multiple assembly locations, even small and midsized manufacturers can have difficulty keeping everyone in their organizations on the same page. If a new standard or regulation affects your assembly process, can you be certain everyone gets the message? If an assembly-related defect is reported in the field, can you be sure the mistake isn’t repeated? You can, with web-based enterprise compliance and quality management software, says Nikki Willett, vice president of marketing and regulatory affairs at Pilgrim Software in Tampa, FL. Pilgrim’s product consists of seven interrelated, customizable modules that cover audit management, training and certification, calibration and maintenance, s u p p l i e r q u a l i t y, document management, complaint handling, and corrective and preventive action Web-based enterprise (CAPA) management. A key feature is the softcompliance and quality ware’s ability to integrate with other software, management software can such as enterprise resource planning systems, help assemblers address manufacturing execution systems, product life quality problems whenever cycle management software, human resources and wherever they occur. software, and call-center systems. Photo courtesy CEA The top priority of any manufacturer is to Technologies Inc. address quality problems whenever and wherever they occur. The CAPA management module captures these problems from multiple sources. “It can be a customer complaint,” says Willett. “It For reprints of this can come from your MES, because of a problem article, please contact on the shop floor. It may be an issue with incomCindy Williams at ing parts from a supplier. It may come from a [email protected] piece of equipment that’s out of spec.” or 610-436-4220 ext. 8516. When a problem is identified, a number of decisions need to be made quickly. Does the production lot need to be contained? Has it already entered the distribution pipeline? Software tracks ■ By John Sprovieri it down. In the case of a medical device, the software can also generate an electronic report for Editor
When updated instructions are logged into the system, the software alerts every operator to the new procedures.
the Food and Drug Administration. At that point, managers can think about identifying the root cause of the problem and how to correct it. Say, for example, an operator was using a machine incorrectly because the work instructions were out of date. The CAPA module can trigger a request to update the instructions in the document management module. The “owner” of the document would know to update the instructions and get any necessary approvals. When the updated instructions are logged into the system, the training and certification module is alerted to ensure that every operator who uses that machine knows the new procedures. This can be as simple has having each operator sign off on the new instructions. “Or, you may want to have the manager confirm that the operators have read it,” says Willett. “Operators may have to go through a checklist or take a small exam. They may even need classroom or online training. ...And because our software can be integrated with other business software, employee records can be automatically updated to reflect that they have completed the training, which they may need for their job certification.” Perhaps the cause of the problem wasn’t an outdated work instruction, but a machine that was out of specification. The calibration and maintenance module can tell management when the machine was last calibrated or serviced, and it can notify maintenance personnel to make an adjustment or replace a part. If the problem was faulty parts from a supplier, the supplier quality module gets triggered. “That could impact the rating of the supplier,” says Willett. “You may want to requalify that supplier. You may even want to change suppliers.” If ISO or FDA certification is necessary, the audit management module can help engineers prepare for audits and deal with their findings. “Auditors will come through with their questions and checklists,” says Willett. “They may find some issues and...make recommendations for improvement. Engineers can use the software to enter their plans for correcting those issues. Some of the auditor’s findings may be so critical that engineers may want to escalate to a A CAPA.”
www.assemblymag.com August 2009 / ASSE M B LY 9
WE FED IT
System Feeds, Assembles Springs 䡲 By John Sprovieri Editor
S
prings are tough to feed. They’re flexible, and they tangle easily. Centricity Corp. has developed a machine, called the Versa-Stack, that overcomes the challenges of feeding and assembling springs and other tubular parts. Recently, the machine was put to the test. It had to stack three cylindrical parts—a ring formed from steel wire, a metal tube, and a small or large coil spring—and place the stack into a larger assembly. The OD of each part was approximately 0.15 inch; the ID was 0.1 inch. The Versa-Stack consists of a vertically oriented servo-driven rotary indexer fitted with a custom dial plate. Mounted radially around the edge of the plate are 35 replaceable pins. Above the plate are two vibratory bowl feeders and two spring feeders fitted with Centricity’s Feedscape systems. The Feedscape is designed to feed parts with The Versa-Stack consists of a servoa high diameter-to-length ratio, such as washers, driven rotary indexer with a custom dial plate. Mounted radially around the edge retaining rings, wave washers, Belleville springs, of the plate are pins for holding tubular seals and bearings. Instead of handling parts by their outer surfaces, it handles parts by their inside parts. Photo courtesy Centricity Corp.
surfaces. The parts are threaded onto a rod and secured by a series of alternating jaws. Parts are free to travel down the rod as the jaws open and close. This maintains control of the part at all times. There is no chance for parts to flip, shingle or fall off. The Feedscape does not require a vibratory inline track, and tooling is inexpensive and flexible. As the dial indexes clockwise to the 11:00 position, a ring is fed from the bowl to a Feedscape, which drops it onto a pin. The dial then indexes to the next position, where the tube is dropped onto the same pin. Next, the dial indexes to the final position, where the small spring is dropped onto the pin. If the assembly requires the large spring, the first spring feeder is bypassed and the second feeder is activated. The stacks are held in place by an integrated retaining system until they reach the 6:00 position. At that point, the stack is threaded onto another Feedscape mechanism, which passes it off to a robot at a rate of 15 per minute. For more information, call 330-545-5624 or visit www.centricity.net.
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Meter-mix Systems Fill Many Niches Meter-mix systems are available for everything from dispensing micro shots to high-volume applications, such as potting, bead laying, form-in-place or filling. They can accommodate a wide range of materials, including adhesives, polyurethanes, resins and epoxies, and are easy to integrate with either a larger automated system or tabletop robot. Systems can be uniquely tailored for any ratio or fluid combination at an affordable price, and come with a guarantee of service. I&J Fisnar Inc. 201-796-1477 www.ijfisnar.com
Modular Automatic Coiling System Is Flexible The modular AutoCoiling System can automatically coil, bind and batch long wires, replacing lengthy conveyors and freeing up valuable floor space. Due to its flexible and modular design, including a separate power supply, the system can be retrofitted to CrimpCenter series machines in the field. It is possible to coil single-wire applications with or without seals or terminals on either end. Accuracy is assured by continuous wire length measurement using a closed-loop system. Schleuniger 603-668-8117 www.schleuniger-na.com See us at ATExpo, Booth 446 www.assemblymag.com August 2009 / ASSE M B LY 13
Automotive Supplier Rides the Winds of Change 䡲 By John Sprovieri Editor
N
ot that long ago, MasTech Manufacturing in Manistee, MI, was riding high. A supplier of conveyors, material handling equipment and welding cells for the automotive industry, the company had won some major contracts, including lines at Freightliner in Cleveland, NC, and BMW in Spartanburg, SC. But then the automotive industry hit the skids. MasTech’s workforce went from approximately 50 people in mid-2008 down to just three. If the company were to survive, it would have to diversify. So, when Reno, NV, startup Mariah Power went looking for a manufacturer to build its new wind turbine for residential and light commercial use, MasTech leapt at the opportunity. It signed a contract with Mariah Power in December 2008, and began converting its 30,000-square-foot facility to make the turbine, a vertical-axis design called the Windspire. All totaled, MasTech spent some $1.5 million on new equipment. “We built robotic [and] manual welding tools,” says John Holcomb, MasTech’s general manager. “We built custom material handling equipment and racking. We bought new machine tools.”
“It’s been our desire since Day 1 to make the largest economic impact in the smallest geographical area.” —John Holcomb, MasTech Production began in April. Since then, the company has been assembling 100 turbines per month—a number that could increase to 1,000 per month within a few years. MasTech has shipped Windspires throughout the United States, as well as internationally, including Israel, Denmark, France and the Netherlands. The company has hired back all the employees who were laid off, and even added a few more. By the end of 2009, the company could have a workforce of 75 to 80 people. “By the end of next year, we hope to employ approximately 120 people,” says Holcomb. “If we start selling more overseas, we could potentially have 500 to 600 jobs in five years.” The Windspire is 30 feet tall and 4 feet wide. It includes a highefficiency generator, an inverter, a hinged monopole and a wireless performance monitor. The 1.2-kilowatt machine will produce approximately 2,000 kilowatt-hours per year in winds averaging 12 mph. From the start, MasTech included local suppliers in the endeavor.
14 ASSEMBLY / August 2009 www.assemblymag.com
Since April, MasTech has been assembling 100 turbines per month—a number that could increase to 1,000 per month within a few years. Photo courtesy Mariah Power
The turbine’s aluminum airfoils are produced by Whitehall Industries Inc. in Ludington, MI. Steel parts come from Alro Steel Corp. in Jackson, MI. The inverters are assembled by Amptech Inc. in Free Soil, MI. Boxes and crates are made by Norton Packaging Corp. in Grand Haven, MI. At least three other Michigan companies are also part of the supply chain. “It’s been our desire since Day 1 to make the largest economic impact in the smallest geographical area,” says Holcomb. “The only components that come from outside the United States are the rare earth magnets, which come from China, but that’s where neodymium is mined.” Holcomb emphasizes that his company’s turnaround should not be considered unique. “We’ve proven that, given the right tools and the right attitude, American workers can compete in the global market by supplying not only a cost-effective product, but a superior product,” he says. “Anyone can do it. We have the technology. If we reapply it and leverage it in new, innovative directions, we can compete with anybody.” 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.
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.
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Assembly Lines
Inventions
Mergers Forecasts New facilities Group Launches Wind Energy Database
The Great Lakes WIND Network has created an online database to help wind energy companies locate suppliers and other renewable energy organizations.
CLEVELAND—The Great Lakes WIND Network, an international wind energy supply chain advisory group, has launched a new web-based WIND Energy Supply Chain Database and Mapping System, available online at http://maps.glwn.org/wind/, to promote the growth of the wind power industry. The site features an interactive map and a searchable wind supply chain database containing the profiles of more than 1,000 manufacturers and organizations in the United States, Canada and Mexico that actively serve the emerging wind industry. Designed to facilitate customer-supplier relationships, the system quickly connects manufacturers and suppliers with OEMs, economic development officials, consultants and other wind power supply-chain partners. “The wind energy sector is the fastest growing industry in North America. By linking buyers, sellers and other industry partners, we believe this system can be a catalyst for business expansion, investment and new jobs,” says network director Ed Weston. “We are very excited at the prospect of being able to service our global network with a single site that supports supply chain needs.” Access to the site is free. To register with the database, visit www.glwn.org, select “Get Listed,” and complete a Wind Capabilities Profile to start the registration process. 16 ASSEMBLY / August 2009 www.assemblymag.com
Deere & Co. Planning Russian Expansion MOLINE, IL—Deere & Co. says it is prepared to “significantly expand its farm, forestry and construction operations in Russia,” as part of the company’s long-term commitment to the region. The remarks came during a recent Russia-USA Business Forum in Moscow, which took place at the same time President Obama was meeting with Russian president Dmitry Medvedev. “We share the vision that Russia can make a significant and sustainable contribution to help meet the world’s growing demand for food, energy and forest products,” says Deere CEO Samual Allen. “John Deere is working to expand its Russian manufacturing capacity for agricultural equipment by early 2010. Ultimately, with the support of the government of the Russian Federation, Deere could envision a series of significant investments over the next five to seven years in expanded capacity for manufacturing and supporting all types of Deere equipment.”
EFD Inc. Wins Solar Award EAST PROVIDENCE, RI— Dispensing equipment manufacturer EFD Inc., a subsidiary of Nordson Corp., has won the 2009 International Solar Cell Award for best technical product. Presented at the 2009 InterSolar Exhibition in Munich, Germany, the award comes in recognition of the company’s new PV cell ribbon and
bus bar attachment methodology: a point-to-point soldering process that uses a lead-free solder paste and flux mixture to attach string ribbon material to silver bus bars during solar module assembly. In addition to eliminating the need for precoating with a liquid flux, the process creates a robust solder joint with minimal microcrack formation. The result is an increased lifespan for the solar modules in which it is used.
Kyzen Opening Malaysia Office NASHVILLE—Electronics cleaning products manufacturer Kyzen is opening a new sales and support facility in Penang, Malaysia, as part of an ongoing effort to increase the company’s market share in the Asia-Pacific region. “The possibility of a Kyzen facility in Southeast Asia has been under consideration for some time,” says Kyzen vice president Tom Forsythe. “Malaysia is an important hub for high value-added electronics and other high-technology manufacturing with a business friendly environment and, most importantly, with a highly educated, dedicated work force.” Founded in 1990, Kyzen provides cleaning products to a wide range of customers, including those in the electronics, metal finishing, medical device, semiconductor and optical components industries.
Volvo Kicks Off Fuel Cell Initiative GOTEBORG, Sweden—Volvo
group is teaming up with Midroc New Technology, the OCAS research center in Belgium and the Swedish Energy Agency to develop and produce a new generation of fuel cells for possible use in everything from trucks to boats. As part of the initiative, the three members are forming a new jointventure company called Powercell Sweden AB, based in Gothenburg, Sweden. The $25 million effort is expected to create some 100 new jobs over the next three years.
Interior Components Company Expanding in Midwest VALPARAISO, IN—UGN Inc., a manufacturer of interior trim products for the automotive industry, will invest about $3 million to expand its production capacity in northern Indiana. The company says it will also add another 100 employees to its payroll by 2014. “UGN continues to grow and celebrate successes in a very challenging economic environment,” says company CEO Randy Khalaf. “Our Valparaiso facility is seeing incredible expansion and is well positioned with new products and technology to see further growth once the global economy starts to show signs of recovery.” Founded in 1986, the company is adding 10,000 square feet of manufacturing space to accommodate a new contract to produce interior components for both luxury automobiles and SUVs. The company also provides components for small trucks.
Power Tool Demand Rising CLEVELAND—Despite the current recession, global demand for power tools is expected to increase 7 percent annually through 2013, according to a recent study by The Freedonia Group. Total annual demand is expected to be about $29 billion by the
end of the study period. The U.S. market will continue to be the strongest, accounting for slightly over a third of total demand. In addition to responding to an eventual turnaround of the current housing crisis, the U.S. market is also expected to benefit from the introduction of new and improved products, such as cordless electric tools. Freedonia researchers say there will also be healthy demand in Brazil, Russia, India and China, with demand in China and India rising about 6 percent annually in the course of the study period. For more on the study, visit www.freedoniagroup.com.
Nordic Windpower Secures DOE Loan BERKELEY, CA—The U.S. Department of Energy has approved a $16 million loan to help Nordic Windpower USA Inc. expand its production facility in Pocatello, ID. The loan is being supported through the 2009 American Recovery and Reinvestment Act, signed into law by President Obama in February. Nordic Windpower manufactures two-bladed, utility-scale wind turbines featuring a flexible “teeterhub” that helps dissipate the force of turbulent winds that would otherwise cause undue wear on the system’s drive train. As part of the expansion, Nordic plans to add another 75 employees to its payroll. “Nordic’s expansion will create new and skilled green jobs to boost the economy and help meet America’s growing energy needs with clean wind power,” says Tom Carbone, CEO of Nordic Windpower. “We appreciate DOE’s vote of confidence in our innovative technology and our business model.”
manufacturer Stäubli Robotics is teaming up with the engineering and integration company Rixan Associates Inc. to coordinate activities in the areas of marketing and sales, with an emphasis on robotic automation services, engineering services, components, software and training. “We are building the future by bringing two world-class organizations together in forming a strategic partnership. This partnership will reinforce our mutual customer-centric commitment in providing first class service and support to our customers,” says Stäubli Robotics division manager Joe Gemma. “We are excited about this new partnership,” says Rixan President Stephen Harris. “Rixan needed robots with higher payloads, faster cycle times and robots that had more application-specific features. Stäubli robots fulfill those needs and will provide our customers with leading-edge technology, high reliability and a worldwide support network.”
Assembly Event Records Strong Attendance NEW YORK—Despite a challenging economy, Canon Communications says attendance was up 3 percent at its recent assembly and medical device trade event in New York.
In all, some 24,000 buyers were on hand for the co-located MD&M East, EastPack, Automation Technology Expo East, Green Manufacturing Expo and Atlantic Design & Manufacturing shows held at the Javits Convention Center in June. “A number of our exhibitors expected that attendance would be down because of the current state of the economy,” says Canon Communications CEO Charles G. McCurdy. “Instead, the success of this event has generated considerable optimism among them about the enduring business vitality of key advanced manufacturing segments, most notably medical devices.” As further evidence of this fact, McCurdy says about two-thirds of the event’s 1,000 exhibitors have already contracted for space in the 2010 show. “The MD&M East Show allowed us to land more than 90 leads, of which 75 percent or more have immediate needs for our products and services,” says Ken Jenkins, president of Ohio-based mold maker Pleasant Precision Inc. “I have displayed at more than 15 trade shows in the past 10 years, and the MD&M East Show provided more substantial leads than all of the other shows together.” For more on Canon Communications, which also organizes the Assembly Technology Expo in Rosemont, IL, sponsored by ASSEMBLY magazine, visit www.cancom.com.
Stäubli, Rixan Associates Joining Forces DUNCAN,
SC—Robotics
Canon Communications’ trade show in New York continues to grow, despite the tough economic climate. www.assemblymag.com August 2009 / ASSE M B LY 17
Assembly in Action
Single-Cable Camera Maximizes Efficiency
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By eliminating the need for any additional cables, the camera minimizes the risk of cable fatigue and greatly improves the integrity of the vision system.
For reprints of any Assembly in Action article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.
omau Group, a subsidiary of Fiat Spa, builds automated production machines for a wide range of customers, including those in the automotive industry. The company also manufactures turnkey automated assembly systems, robots, weld guns, conveyors, recognition software and other automation components. Recently, engineers at the company’s North American headquarters in Southfield, MI, developed what they call VersaVision II software as an upgrade to the company’s existing robotic guidance systems. The new software allows a robot to both pick up parts and then position them in space using a single machine-vision camera, as opposed to multiple cameras. The software can be used with any GigE camera or robot currently on the market. By reducing the number of cameras, the system helps assemblers reduce costs. “The VersaVision II program provides our robots true visual recognition,” says Comau product development engineer Max Falcone. “The software emulates the visual cortex of the human brain, teaching the system to recognize an object the same way you would teach an infant. We show the system an object by taking a picture of the object and naming it. All of the information pertaining to that object is
18 ASSEMBLY / August 2009 www.assemblymag.com
stored into the system’s memory, which allows the system to recognize the target part and maneuver a servo-actuated manipulator to pick, place or work on that object.” To make the system as effective and efficient as possible, Comau engineers wanted to reduce the amount of cabling connecting the robot-mounted camera to the robot controller. Standard GigE cameras require three cables: one for communications, one for power and one to trigger the camera to take a picture. Three cables means three times the opportunity for failure in a single camera application.
Comau engineers wanted to reduce the amount of cabling connecting the robot-mounted camera to the robot controller. “To make our robotic guidance systems as reliable and cost-effective as possible, we wanted to take our design one step further,” says Comau robotics and vision products manager Tony Ventura. “Not only did we need to reduce the number of cameras in our systems, we wanted to reduce the chances of system failure associated with cabling. The more cables located on a robot, the higher the risk of cable failure.” To solve the problem, Comau incorporated a TXG camera with power over GigE cabling from Baumer Ltd., a manufacturer of sensors, motioncontrol equipment and machine vision. In the Comau application, the camera includes a specially developed industrial power injector module or Ethernet
off parts that are incorrectly To develop the application, Rixan oriented and allow through engineers first used the Melfa-Vision only those parts that are po- software to calibrate the robot in relasitioned correctly. tion to the feeder. They then put a part Historically, because of in the robot gripper and “jogged” the the various hard-tooled robot over to the feeder where it set the orientation features that part down on the plenum. In this way are required, this kind of engineers “taught” the robot to pick up equipment has been very the part in this orientation and at this part-specific. However, the point on the plenum. robotics company Rixan Once the robot had been taught how Associates Inc. has devel- to pick up the part, Rixan’s engineers oped a new flexible vibrato- used the Cognex camera’s PatFind The new software allows a robot to both pick up parts and ry bowl feeder that includes object-location tool to draw a rectangle position them in space using a single camera. a robot and machine vision around the part on the screen, thereby system to orient multiple allowing the vision system to automatiswitch that provides power down a Cat6 parts using a single system. cally recognize the part as it moves Ethernet cable at distances up to 100 Rixan originally developed the across the plenum. meters. By eliminating the need for any system to load dozens of different In operation, when it sees a part, the additional cables, the Power over GigE aerospace fasteners into a press, a system first sends a signal to stop the Camera minimizes the risk of cable fa- task that was previously tigue and greatly improves the integrity performed by hand and of a vision system. would have otherwise According to Falcone, Comau also required installing many liked the camera because of its robust different feeders to design and performance features. “The automate. camera is neat, complete and well engiThe new system emneered. The lock-style connections are ploys a vibratory bowl strong, reliable, industrially accepted feeder that randomly presM8 connectors. The integrated UV ents the parts to the vision filter mounted in front of the camera’s system, which in turn, face eliminates the need to buy and in- stops the feeder when it stall a separate filter to show true col- sees the correct part in ors. This high-quality camera allows us the correct orientation so to provide our customers with an over- that a robot can load the all lower cost system,” he says. part into the press. The The system employs a vibratory bowl feeder that randomly For more on machine vision, visit parts are presented on a presents the parts to the vision system, which in turn, stops the feeder when it sees the correct part in the correct orientation. www.baumerelectric.com/usa or call semitransparent, backlit 800-937-9336. plenum, so the vision sysFor more on automation, call 248- tem can easily identify them. The parts feeder. After the feeder has stopped, the 353-8888 or visit www.comauinc.com. that are not picked automatically recycle vision system acquires one last image to into the bowl. The result has been a 20 determine the exact position of the part percent increase in productivity and one and calculate its angle of presentation. less operator to tend the press. The robot then moves to the location Critical to the success of the system of the part, twists its wrist to match the has been its In-Sight 5401 vision sys- part’s orientation, picks up the part and raditional vibratory bowl feeders use tem from machine vision manufacturer sends a signal to restart the feeder. a helical shelf-like inclined ramp Cognex Corp., which is integrated with Most of the parts in the aerospace winding up from the bottom of a bowl an RV-6SL-S11 robot and Melfa-Vision fastener application are symmetrical to a discharge passageway. The pas- software from Mitsubishi Electric. top to bottom so they can be identified sageway’s reciprocating motion pushes Rixan chose the In-Sight 5401 because from their silhouette alone. However, the parts up the ramp. Obstructions, of its processing power and the fact that in those instances where a part has two cutouts and other orienting devices are it can acquire up to 60 complete eight- distinct sides, the Cognex PatMax tool arranged along the passageway to topple bit images per second. can be used to recognize which side is
Vision Enables Feeder to Handle Multiple Parts
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Assembly in Action
up. Top-down lighting is used options like speed enhancefor parts in which pattern ment, next-generation unrecognition is required. White derstencil cleaning technollight is used for some parts, ogy and automatic board while glare-free polarized support, as required. lighting is used for others. “It’s no coincidence that “A key to the success of DCI has been named to this application is the ease-ofFortune Small Business setup, accuracy and reliability magazine’s list of the fastest of the Cognex In-Sight vision growing small companies sensors,” says Rixan Associfor the past two consecuates President Stephen Hartive years,” says DCIs viceris. “The PatMax tool that we president of business develuse to recognize part features opment Jay Gillam. “When is much faster and more acyour top priority is ensurcurate than other comparable ing your customers receive industry tools that we have outstanding service and suseen. The easy integration beperior quality products on tween Cognex vision sensors time every time, business The screen printer’s scalability means it can be modified to meet DCI and Mitsubishi robots drasti- Inc.’s future manufacturing needs as well as those in the present. success is inevitable. Our cally reduces the amount of addition of DEK’s Horizon time required to develop vision-enabled system’s quick setup and changeover 03i is just one more example of this robot applications and in most cases times, as well as its new HawkEye print commitment.” eliminates the need for writing a single verification inspection feature. For more on custom electronics manline of code.” “We evaluated several screen printing ufacturing, call 888-824-9412 or visit For more on machine vision, call 508- systems,” Morgan says. “The capability www.dciincorporated.com. 650-3000 or visit www.cognex.com. of DEK’s Horizon 03i coupled with For more on screen printing systems, For more on parts feeding and the staff’s depth of knowledge and visit www.dek.com. automation, call 937-438-3005 or visit process expertise made our decision an www.rixan.com. easy one. With the Horizon platform’s new scalability, future-proofing and ability to customize, we can modify the system to meet our manufacturing ne of the goals of the school of requirements as our business changes architecture at the University of and grows.” CI Inc., in Olathe, KS, designs and DEK’s entire manufactures electronics compo- Horizon line of nents and subassemblies for custom- screen printers ers in a wide range of industries. The includes mocompany specializes in the design and torized stenmanufacture of specialized custom liq- cil alignment, uid crystal displays, light emitting di- fast product ode displays and operator interfaces. changeover, 2.0 Recently, the company expanded its Cpk print proelectronics manufacturing capacity by cess capability implementing a new Horizon 03i fully and Six Sigma automatic screen-printing system from production perelectronics assembly equipment manu- formance. The facturer DEK USA Inc. system’s InAccording to DCI chief operating stinctiv V9 user officer Mike Morgan, the company interface allows went with the Horizon 03i because of manufacturers When the school of architecture at the University of North Carolina went its high print quality and ease of use. to seamlessly in- shopping for new workbenches, it ended up going with a set of stations Morgan says his company also likes the tegrate advanced from industrial workstation manufacturer Lista International.
Screen Printer Adapts to Changing Needs
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Workbenches Harmonize With Design Goals
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North Carolina in Charlotte is to help students “apply strategic thinking to environmental problems.” It was therefore only natural that when the school needed a new set of work desks, the students should take part in the selection process. “Our existing desks had worn out their welcome,” says Ken Lambla, dean of the university’s college of arts and architecture. “The old desks were custom-designed and custommade when we first occupied our building in 1991. They may have been sufficient then, but today they didn’t offer the kind of flexibility the students’ work demanded. Not only were the dimensions and ergonomics insufficient, but they were lacking in many key areas of functionality: no power supplies, no wheels for mobility, inadequate display surface, and serious storage limitations.” Ultimately, after consulting with a student-run focus group and putting the project out for bid, the college replaced more than 200 of its old desks with a set of Arlink workstations from industrial workbench and cabinet manufacturer Lista International Corp. According to Rich Preiss, the school’s director of laboratories, the school chose the Arlink workbenches because they were rugged, functional and aesthetically pleasing. Lambla adds that Lista was also very responsive in terms of meeting the school’s particular needs. “Being architects, we’re pretty detail driven,” he says. “We needed a company that was going to work with us on the exact details of fabrication as it relates to the experience we’ve had over the last 15 years. Lista brought a lot of knowledge to the table and demonstrated an ability to create custom application-specific solutions.” Lambla adds that the company was able to work within a narrow time frame, another reason the college went with the Arlink desks. “We needed somebody who could
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supply these workbenches within a very tight window of time—about eight weeks to be exact. This included about one week for delivery and installation,” he says. “At the university level, we call the money that’s left over from the annual budget ‘one-time money.’ This is what we were working with, and if
we didn’t use it by the given deadline, we’d lose it. Fortunately Lista came through, not only on time, but with completely assembled products. Many of the other bidders were delivering only parts. Lista provided a ready-to-use solution.” For more on workstations, call 800722-3020 or visit www.listaintl.com.
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ASSEMBLY
Medical Device Assembly
Better One or Better Two? Ophthalmic device manufacturers keep an eye on new technology.
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Because of the aging population, there will be a huge demand for ophthalmic devices over the next four decades. Photo courtesy Carl Zeiss Meditec AG
one of the most dynamic market segments in the medical device industry. An aging population, proposed federal healthcare reform and an increasing number of elective surgeries, such as Lasik treatment, is creating a huge demand for diagnostic instruments, surgical equipment, lasers, intraocular lens implants, shunts, artificial retinas and other products.
By Austin Weber Senior Editor
s most people age, they become wiser. But, gradual vision loss is something that even the smartest people in the world can’t avoid. That simple fact of life is good news for the ophthalmic device industry. Cataracts, glaucoma, macular degeneration, presbyopia, diabetic retinopathy, posterior uveitis and other visionrelated conditions make ophthalmology
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Approximately 50 percent of all adults in the United States don’t have 20/20 vision, because they are nearsighted, farsighted or have an astigmatism, which is an irregular curve of the cornea. By 2020, the number of people who are blind or have low vision is projected to increase dramatically. “Blindness or low vision affects 3.3 million Americans age 40 or over . . . and this figure [will] reach 5.5 million by the year 2020,” says Elias Zerhouni, M.D., director of the National Institutes of Health (Bethesda, MD), which operates the Eye Disease Prevalence Research Group and the National Eye Institute. “As our population lives longer, eye disease will be an ever greater concern. Low vision and blindness increase significantly with age, particularly in people over age 65.” A recent study conducted by RTI International (Research Triangle Park, NC) and the Centers for Disease Control and Prevention (Atlanta) predicts there will be a huge demand for ophthalmic devices over the next four decades. “The aging U.S. population will lead to a large increase in early and advanced age-related macular degeneration,” claims David Rein, a senior research economist at RTI. “By 2050, the number of people with early age-related macular degeneration will double to more than 17.8 million,” Rein points out. At the same time, he expects the number of cases of diabetic retinopathy, which is the leading cause of blindness among working-age adults in the United States, to increase from 5.5 million to 16 million.
“The good news is that medical technologies are changing rapidly,” says Rein. “Ten years ago, there were no treatments for age-related macular degeneration. With luck, tomorrow’s discoveries will lead to far greater reductions in visual impairment and blindness.” According to MedMarket Diligence LLC (Foothill Ranch, CA), the worldwide ophthalmic products market exceeds $22 billion and is growing at more than 10 percent annually. The industry is dominated by several major players, such as Abbott Medical Optics Inc. (Santa Ana, CA), Alcon Laboratories Inc. (Fort Worth, TX), Bausch & Lomb Inc. (Rochester, NY) and Carl Zeiss Meditec AG (Jena, Germany). However, numerous small start-up companies specialize in niche segments, such as cataract, corneal or refractive surgery. No matter the size of the company, ophthalmic manufacturers are focusing their efforts on making surgical procedures faster, easier, more accurate and more affordable. There’s also a growing trend toward drug-device combination products. Diagnostic Tools Traditionally, the ophthalmic industry is divided into two main segments: diagnostic instruments and surgical devices. Diagnostic instruments are used by ophthalmologists to examine their patients. They include refractors (the “better-one, better-two” device that’s used in conjunction with an eye chart), slit lamps (an upright microscope equipped with a bright light) and tonometers (a device that measures eye pressure). Ophthalmologists are always looking for equipment that makes them better clinicians. They want instruments that provide information that allows them to make better diagnoses and more efficient treatment decisions in a patient-friendly manner. “The latest trend is toward noninvasive diagnostic imaging,” says Andrew Shatz, M.D., an ophthalmologist at the Woolfson Eye Institute (Atlanta). “High-speed ultrasound
A wide variety of diagnostic instruments are used by ophthalmologists to examine patients, such as slit lamps. Photo courtesy National Eye Institute
and scanning laser tomography are both giving increasingly sharper resolution of the microscopic structures of the eye, allowing for a more detailed view of pathology. “This has also allowed us to visualize the relationship between the different regions of the eye in a way we have never been able to before, without having to resort to intravenous dye injection,” explains Shatz. “More doctors are adopting technology that allows us to image the back of the eye without the need for dilation.” “We now have incredibly precise
imaging devices called OCT (optical coherence tomography) that allow us to create microscopic images of structures inside the eye that were never before visible,” adds John Hovanesian, M.D., an ophthalmologist at Harvard Eye Associates (Laguna Hills, CA) and a clinical instructor at UCLA’s Jules Stein Eye Institute (Los Angeles). “This greatly aids in diagnosis of conditions like diabetic eye problems, eye tumors and macular degeneration.” An OCT allows an ophthalmologist to construct three-dimensional images of living eye tissue with better resolution
The human eye is a complex, delicate organ. Common back-of-the-eye diseases include age-related macular degeneration and glaucoma. Illustration courtesy American Academy of Ophthalmology www.assemblymag.com August 2009 / ASSE M B LY 23
Medical Device Assembly than a traditional MRI scan. the world’s first noninvaBetter yet, the procedure sive early detection device can be performed in a for cataracts, the leading doctor’s office instead of a cause of vision loss worldhospital. wide. The new device is Today’s new breed of based on a laser light techdiagnostic instruments use nique called dynamic light state-of-the-art technology scattering (DLS). to objectively measure and It was initially develquantify vision disorders. oped to analyze the For instance, engineers at growth of protein crystals Optos Inc. (Marlborough, in a zero-gravity space MA) recently developed environment. The tablea new type of imaging top DLS device is used device that provides an to detect the earliest damultra-widefield view age to lens proteins, trigof the retina. It allows gering an early warning ophthalmologists to see This telescopic implant is 4 millimeters long and contains two wide-angle glass for cataract formation and lenses. It is designed to treat age-related macular degeneration. Photo courtesy more than 80 percent of VisionCare Ophthlamic Technologies Inc. blindness. the retina, compared to a “Much of the work [in traditional camera that provides a much Researchers at the National Eye Insti- the diagnostic instrument field] is going narrower view—about 11 percent. The tute (Bethesda, MD) and the National into finding ways to treat presbyopia to device uses scanning coherent laser Aeronautics and Space Administration enable people to get rid of their reading light rather than full spectrum white (NASA, Washington, DC) recently glasses,” says James Ohneck, CEO of light that’s typically used by cameras adapted a compact fiber-optic probe Oculatek Inc. (Cleveland). The start-up and other forms of ophthalmoscopy. developed for the space program into company has developed a transscleral
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light therapy system that uses a low level of infrared light at a specific wavelength. “It helps strengthen the ciliary muscle, which weakens as the eye ages and is one of the factors that leads to the eye’s inability to accommodate,” Ohneck points out. “It is therapy, not surgery,” adds Ohneck. “The patient has several short therapy sessions where they look into a binocular while the eye is dosed with infrared light. The treatment does not harm the eye and there is no pain associated with the procedure. It’s unique because it is the first device of its kind to therapeutically treat presbyopia without an invasive surgical procedure. Newer technologies being developed involve implanting special lenses through a surgical procedure or modifying the shape of the eye to adjust vision.” Even noninvasive ophthalmic procedures must be cleared by the U.S. Food and Drug Administration (FDA, Washington, DC), which often hinders start-up manufacturers and prevents
asb08094dymax.indd 1
them from quickly ramping up production. For instance, Oculatek’s device is still undergoing trials with the FDA. If approved, it won’t be readily available to ophthalmologists for several more years. “The challenges around new devices are regulatory in nature, such as getting FDA approval and validating the efficacy through clinical trials,” says Ohneck, who holds a degree in electronic engineering. “This takes time and money. Investors are reluctant to put money into products that don’t have the trials, so it’s a chicken and egg; you need money to do clinicals, but you can’t get it until the clinicals are completed.” To reduce costs, many start-up manufacturers outsource assembly to third parties. For instance, Oculatek is working with Valtronic Technologies Inc. (Solon, OH). That allows Ohneck and his colleagues to focus their attention on product development. Ophthalmic devices are typically
assembled in clean rooms. Large manufacturers, such as Alcon, have recently been focusing their efforts on ergonomics and automation. Alcon’s Fort Worth plant recently celebrated its 50 anniversary, and the company is currently building a new facility in Singapore to supply the fast-growing Asian market. “In our more manual assembly areas, we have invested in adjustable workstations and eliminated microscopes to make our operators more comfortable,” says Melissa Mota, a company spokesperson. “In addition, we have invested heavily to automate mid- and higher-volume operations and products. Our focus has been on advancing our assembly processes to be flexible with high-mix automation, in order to satisfy increasing demand for our products.” Implantable Devices One of newest technological advances on the surgical side of the ophthalmic device industry is the correction of presbyopia, which affects 90 million people
See us at ATExpo, Booth 1233 www.assemblymag.com August 2009 / ASSE B LY 25 7/14/09M10:20:55 AM
Medical Device Assembly
An OCT allows ophthalmologists to construct three-dimensional images of living eye tissue with better resolution than a traditional MRI scan. Photo courtesy Carl Zeiss Meditec AG
in the United States, with multifocal and accommodating implants. “These not only improve distance vision without glasses, but also decrease the need for readers,” says Shatz. “This market has been heating up over the last few years. What has started out with three competing lens models will [eventually] blossom to 10 or more different
This fiber-optic probe uses NASA-developed technology to detect cataracts. Photo courtesy National Eye Institute
technologies, all aimed at achieving the holy grail of ophthalmology. “The new revolution is almost at hand,” claims Shatz. “Improved lens and cataract surgery technology, in combination with the baby-boomer generation now developing cataracts, has created the perfect breeding ground for presbyopic lens implants. This technology
will overtake laser vision correction as the primary means of correcting vision in the next five to 10 years.” Intraocular lenses (IOLs) are typically made of either acrylic or silicone. Early versions were made of an acrylic polymer called PMMA, which is what led to the discovery of using IOLs in cataract surgery.
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with an IOL. The hybrid devices are designed to treat the most common postoperative complications, such as inflammation, infection and secondary cataracts. “Drug therapy ease of use is of considerable importance as the world’s population continues to age,” says Tracy Klein, CEO of Inson Medical Systems Inc. (Bellevue, WA). “There is a considerable opportunity to reformulate
INTRODUCING THE
older pharmaceuticals into implantable devices. Eye drops are the standard of care for most ophthalmic diseases, yet they have poor penetration into the eye and are inconvenient for patients to administer, often with four to six times per day dosing.” Klein’s company is developing frontof-the-eye drug delivery beads that are smaller than a grain of rice. “We plan to utilize this expertise on future products
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The latest trend in IOLs is toward corrective, foldable lenses that are structurally designed to minimize secondary cataracts from occurring. Most companies developing intraocular implants are focusing their efforts on devices that treat back-ofthe-eye diseases, such as glaucoma and acute macular degeneration. For instance, Alcon recently unveiled the third generation of its Restor lens. The multi-focal device contains 12 concentric “steps” around the optic zone of the lens, which appear as rings. They create different focusing levels from near to distant vision. The surgical procedure is painless and only takes about 20 minutes. Some ophthalmologists are recommending the procedure as an alternative to the more controversial Lasik treatment. In addition, engineers and doctors are currently developing polymeric drug delivery devices that are implanted at the time of cataract surgery along
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Medical Device Assembly
Ophthalmic devices, such as intraocular lenses, are typically assembled in clean rooms. Photo courtesy Carl Zeiss Meditec AG
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for back-of-the-eye applications,” he explains. “We are also in very early development discussions with potential partners who are interested in utilizing our technology to create IOLs capable of drug delivery.” Implantable intraocular lenses pose numerous manufacturing challenges. “The main challenge for us is to make a device small enough to be inserted with the lens, yet big enough to hold enough drug,” says Klein. “There are also technical challenges to overcome with existing injection molding techniques when making devices this small.” For instance, lenses must be extremely thin to be flexible and comfortable to patients. Klein believes the ophthalmic device industry may be able to adapt existing semiconductor manufacturing technology and equipment if devices get smaller. “[However], ophthalmic implantable devices must be as long-acting as possible for obvious reasons,” says Klein. “Therefore, they are unlikely to get much smaller. In addition, surgeons generally want devices they can retrieve if necessary.” “The goal at the moment is to achieve better efficacy with less invasive procedures,” notes Paul Ashton, M.D., president of pSivida Corp. (Watertown, MA). “There are a lot of blinding diseases for which there are no drug treatments yet approved. These diseases include dry age-related macular degeneration (AMD) and diabetic retinopathy.
See us at ATExpo, Booth 615 28 ASSEMBLY / August 2009 www.assemblymag.com
“Recently, there have been some drug treatments approved for wet-form AMD, but this typically consists of an injection into the eye every couple of months,” Ashton points out. “A [more] effective and less invasive treatment for this disease [would] be quite an advantage.” Ashton and his colleagues have recently developed a variety of ophthalmic devices for either implantation or injection into the eye. The devices are made from a proprietary porous silicon material. Vitrasert was the first sustained release device approved for back-ofthe-eye applications. It’s about the size of a pepper corn (6 millimeters long and 2.5 millimeters wide). The device is surgically implanted into the eye, where it releases drugs for six to eight months. “Because the drug is released directly into the eye, it requires approximately 20,000 times less drug than would be needed if given intravenously,” says Ashton. Retisert is a smaller device that is 5.25 millimeters long and 1.5 millimeters wide, or about the size of a grain of rice. It lasts 2.5 years after implantation into the eye. “As it releases its drug directly into the eye, it delivers about 200,000 times less drug than would be needed if the patient took the drug orally,” claims Ashton. It is the only FDA-approved treatment for posterior uveitis, a potentially blinding disease. “Implanting either Vitrasert or Retisert
Your Global Distributor of Adhesives, is a little like having a cataract operaSealants and Assembly Equipment tion,” says Ashton. The next step in the evolution of this series of implantable devices is called Electronic Assembly Iluvien. The device is much smaller & Protection than Retisert (only 3 millimeters long and 0.5 millimeter wide), but it’s Thermal Management designed to last about the same length Solutions of time. “It’s about the length of an UV Curing Systems eyelash and is small enough to fit into & Accessories a needle,” says Ashton. “This allows it to be injected directly into the eye in Dispensing Equipment an office visit [as opposed to outpatient & Surface Preparation surgery, with fewer complications]. The procedure is also far cheaper.” According to Ashton, future ophthalmic devices will continue to ellsworth.com/Assembly.html get smaller and more sophisticated. “Bioerodible systems are already in early stages of testing,” he points out. “Applying existing semiconductor [manufacturing processes] and nanotechnology [will create] ‘intelligent’ devices that respond ISO 9001:2000 to a disease or tell a physician if they are Visit our website and chat with the Glue DoctorTM about an adhesive assembly solution. about to run out [of a drug].” In addition to improved lens implants www.ellsworth.com 877-262-6029 and drug-device hybrids, another new device that intrigues many ophthalmologists is the artificial retina. “This device has given hope to patients asb08094ells.indd who 1 7/14/09 have lost vision from disabling retinal diseases such as macular degeneration,” says Shatz. “While the resolution is currently only able to allow for ambulatory vision, higher resolution electrode arrays under development will be able to differentiate letters and objects.” The artificial retina, called Argus II, is being developed by engineers at Oak Ridge National Laboratory (Oak Ridge, Micro-Percussion Scribing Laser Marking TN) and the University of Southern California (Los Angeles). It consists of an array of 60 electrodes that are attached to the retina. The electrodes Contact us for in-plant conduct information acquired from an analysis and demos. external camera to the retina to provide a rudimentary form of sight. The device has already been implanted in Tag Marking 2D Coding six patients. A newer, higher resolution & Reading model will be available within the next few years. A 800-394-9101
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www.assemblymag.com August 2009 / ASSE M B LY 29
ASSEMBLY
Parts Marking
When All You Need Is a Dot Marking parts with colored inks or stains is a fast, easy way to differentiate between similar-looking components, indicate pass-fail status or confirm that a specific process has been performed.
Parts such as calibration screws can be marked with stains that only become visible under ultraviolet light to indicate whether they have been tampered with. Photo courtesy ITW DYKEM
By John Keating Business Unit Manager, ITW DYKEM Olathe, KS and Claude Bergeron Product Line Manager, EFD Inc. East Providence, RI
M
anufacturers mark parts for many reasons: to differentiate between similar-looking parts; to indicate that a process has been performed or a quality check has been passed; to facilitate assembly; or to link a product or component to the assembly line or machine on which it was produced. Parts like calibration screws may even be marked with stains that only become visible under ultraviolet light to indicate whether they have been tampered with. One of the most common uses of color marking is to make it easier to tell the difference between parts that look similar. Although such parts may be marked with numbers, letters or some other i d e n t i fi e r, s o m e companies choose to color-code them as well, to speed and simplify identification on the shop floor. For example, two springs may appear identical, but may function very differently. Marking each one with a different color stripe is a simple way to tell them apart. Another major use for parts marking systems is in quality control. Parts are often marked after a test has been performed to indicate whether they have passed or failed. Parts are also marked to indicate that a particular process
30 ASSEMBLY / August 2009 www.assemblymag.com
has been completed. This is especially useful if that process does not visibly change the parts. Marking systems are often integrated into testing or production fixtures. An example is a flywheel that gets mounted on an engine with multiple bolts, which are then simultaneously tightened. When all of the bolts have been torqued to specification, the marking device moves into position and applies a dot to confirm that the operation was performed correctly. If the dot is not there, operators downstream will immediately know that additional inspection or corrective action is required.
Clogging can be minimized by using a low-volume, lowpressure spray system. Parts are also frequently marked with color to facilitate assembly processes. For example, assemblers may put a dot of stain on brake calipers to confirm that pads have been installed before mounting rims and tires. Or, a shaft could be marked to indicate which end to insert. Marking is also used in automotive and other stamping processes to check the contours of stamped parts during setup to indicate whether a bend has the correct radius or a crease is straight. In applications like this, color marking provides an easy way to point out any
discrepancies so the operator can fine-tune the press setup. Three Marking Methods Common part marking methods include handheld valve-actuated markers, contact marking systems that press a stain-saturated pad against the part, and noncontact spray marking systems. The simplest of all marking “systems” are handheld valveactuated markers, which are often used in processes such as filling an automatic transmission with fluid and then marking the dipstick for visual confirmation. Contact marking systems consist of an ink or stain reservoir fitted with a pad or dauber and mounted on an air cylinder or similar device. As the part moves into position or the test or process is completed, the actuator advances to press the saturated dauber against the part. Depending on the marking fluid, the parts may need to be clean and dry to achieve an acceptable mark. Noncontact marking systems typically use a pneumatic spray valve to apply spots, stripes and bands, with stain supplied from a tank or disposable reservoir. Depending on the application, the valve can be mounted in a fixed location or attached to an actuator that moves it to the part. In some processes, the part is rotated while the valve applies a band of color around the outer circumference. Pigment and Maintenance Marking fluids are commonly referred to as inks, staining colors or paints, and generally fall into one of two classifications: transparent or opaque. Transparent staining colors have a thinner viscosity than opaque stains and dry slightly faster. They are typically used on lighter colored substrates or in
marking applications involving tight tolerances, such as engine rods. Transparent stains will not settle or separate. Opaque stains use more pigment to produce a heavier mark, and perform well on both light and dark substrates. These stains apply slightly thicker than transparent stains and take slightly longer to dry. Thickness can be adjusted by adding thinner. Because they contain more pigment, opaque stains will settle over time, and daubers will need to be periodically agitated to work properly. Opaque stains also increase the likelihood of spray nozzles clogging and requiring maintenance. Nozzle clogging is a common problem with spray valves, particularly when using heavily pigmented, opaque paints and stains. To avoid applying a thick, heavy spray mark that is slow to dry, valve stroke is usually shortened to “choke down” the aperture to reduce coating thickness. This causes the pigment to be filtered out of suspension at the valve nozzle, causing it to clog. Clogging can be minimized by using a low-volume, lowpressure (LVLP) spray system to apply the stain. Because LVLP designs work with lower pressures and flow rates than standard spray systems, a longer valve stroke can be used. This leaves more space around the valve needle, which reduces the possibility of pigment building up to the point where it eventually blocks the valve nozzle. Separation is another issue with many pigmented stains. This occurs when the pigment separates from the carrier and settles to the bottom of the reservoir, resulting in fainter, less consistent marks that may not be picked up by visual scanning systems.
This spray valve has a dual-ported fluid head. A programmable air delay after each shot keeps the nozzle clean and reduces clogging and maintenance. Photo courtesy EFD Inc.
This spray marking system uses a motorized gear pump to keep pigmented inks in suspension and constantly circulating through the valve. Illustration courtesy EFD Inc. www.assemblymag.com August 2009 / ASSE M B LY 31
Parts Marking spray marking system is an example of this type of equipment. A motor-driven gear pump pulls fluid from the reservoir and supplies it to the spray valve, where it enters one side of the fluid head and exits the other. As fluid is returned to the reservoir, it produces a slight agitation that keeps the pigment from settling at the bottom of the tank. Because as little as 1 psi is sufficient pressure to keep the marking fluid constantly recirculating, a long valve stroke can be used to maintain open space around the valve needle, while a programmable air delay after each shot keeps the nozzle clean and further reduces the risk of clogging.
A simple dot of color can differentiate between similar-looking parts; indicate that a quality check has been passed; or link a product to the assembly line or machine on which it was produced. Photo courtesy ITW DYKEM
Both issues—clogging and separation—can be prevented with an LVLP spray marking system with a double-ported fluid head and
a recirculating pump that keeps the marking fluid moving so the pigment remains in suspension. EFD’s new 781RC recirculating
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Choosing a Marking System When comparing contact and noncontact marking systems, engineers should consider these factors: 䡵 marking speed. 䡵 the cost of the marking fluid and need to maintain inventory (individual stain bottles and applicators vs. less expensive bulk bottles). 䡵 the need to regularly monitor the system to ensure ink is in the bottle vs. using a tank that can be filled once at the start of a shift. 䡵 time needed to change ink bottles or refill a tank and whether the line must be shut down to do this. 䡵 time and cost of replacing contaminated or dried out pads and daubers. Once maintenance requirements, downtime, fluid costs and line speeds have been considered, a noncontact spray marking system often proves to be a more economical long-term choice. 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 parts marking, visit www.assemblymag.com to read these articles: 䡲 On Your Mark. 䡲 Rubber Stamping Assembly. 䡲 The Expanded Reach of Laser Marking.
Assemble it faster, better, for less. Find cost saving new products, technologies, and ideas at ATExpo.
EXHIBITION & CONFERENCE
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ASSEMBLY
Electronics Assembly
Riding the Mini Wave Automated selective soldering technology saves EMS facilities time and money.
Molten solder is pumped through this small nozzle to create a fountain with a directional or spherical shape.
By Reed Gaither CEO RPS Automation LLC Spokane Valley, WA [email protected]
S
elective soldering with a miniature wave or fountain of molten solder offers many advantages compared with conventional wave soldering equipment. It requires less energy, generates less dross, provides more control, and can reach certain joints that would otherwise be inaccessible. Moreover, there’s no need for custom-made pallets or shielding for the boards. These systems can be equipped with a single circular nozzle 2 to 20 millimeters in diameter, a rectangular nozzle 4 to 8 inches long, or multiple nozzles for soldering more than one joint simultaneously. Molten solder is pumped through the nozzle to create a fountain with a directional or spherical shape. In some systems, the printed circuit board is held stationary, and the solder fountain moves beneath it to solder pins, rows and connectors. The fountain travels in three axes (X, Y and Z) up to solder points and down and around bottom-side components. Precise motion control and the small size of the wave prevent damage to nearby components and pads. Other systems hold the fountain stationary and move the PCB. Often referred to as “top-side gantry” systems, these machines can position boards
34 ASSEMBLY / August 2009 www.assemblymag.com
along two additional axes of motion: tilt and rotation. These fourth and fifth axes enable the solder wave to get around bottomside components and penetrate areas that otherwise could not be reached by a three-axis system. In addition, top-side gantry systems can tilt boards for angled soldering, which can improve yields. Different Strokes: EMS Views Change is a constant in electronics assembly. New alloys, fluxes and temperature demands are the norm. Production volumes increase and decrease quickly, and design life
“We have decreased the cost of labor by at least half.”—Todd King, E.I. Microcircuits cycles can be short. Floor space is at a premium, and there is a constant push to reduce costs, increase productivity and improve quality. In this environment, assemblers must run lean, green and mean. This has opened up opportunities for selective soldering technology. Dave Sackett is a consulting engineer in Maplewood, MN, who has worked with many electronics assemblers. He recommends selective soldering systems driven by precision servomotors, as opposed to inexpensive stepper motors. Automatic loading is also a good feature.
“Handling of PCBs should be tool-free when possible,” he says. “Some systems use expensive and time-consuming tooling for different sizes of PCBs. [This] can substantially reduce the usefulness of the system as an economical and high-mix production tool.” Programmability is particularly important for any machine in a high-mix assembly environment. “Software should provide a simple user interface and utilize scanned images or Gerber data,” Sackett says. “It should only take minutes to select solder points and nozzle configurations. A simple jog-toteach set-up camera could also be used to program a board,” he says. For high-mix production, the system should be able to store an unlimited array of soldering programs. To save time and prevent errors, programs can be triggered automatically through a bar code reader. Filling a Gap In the past, high-mix, lowvolume assemblers had two choices for assembling mixed-technology boards: wave soldering or manual soldering. “Our first choice was always wave soldering,” recalls Todd King, vice president of operations at E.I. Microcircuits Inc. in Mankato, MN. “It is the highest volume and the most economical. What prevents wave soldering are unique components and some tight configurations particularly in [radio frequency applications], or large components that cannot be waved or masked. Then we [reverted] to hand soldering.” With production runs between 500 and 10,000 pieces, manual soldering is costly, not only in terms of labor, but also in quality control. Two years ago, the company invested in its first selective soldering system. Today, it has three in-line machines running both lead-free and standard boards. E.I. Microcircuits assembles many boards that require significant
masking or large copper ground planes, which are difficult to solder manually. Selective soldering with a mini wave provides constant heat like traditional wave soldering equipment, but with less waste. “We expect volumes to increase in these applications,” King says. “[These boards] will go directly to selective soldering, bypassing wave or hand soldering entirely.” In the past, E.I. Microcircuits would sometimes run mixedtechnology assemblies through a wave soldering machine and then another soldering operation for difficult through-hole components. Now, these assemblies go directly to the selective soldering system. “It can get in-between deep, tight parts and navigate around large components with consistent repeatability,” says King. “You simply can’t get that manually, regardless of how adept the operators might be. ...We have decreased the cost of labor by at least half [using selective soldering],” he says. Replacing Wave When Ayrshire Electronics first began looking at selective soldering technology, it had some concerns. James Beard, director of manufacturing for Ayrshire’s Oakdale, MN, facility, says the first machines he looked at were not flexible or easy to program. “Everything was customized,” he recalls. “You designed the board, and then you had the selective soldering [machine] designed around it. If you needed fast changeover, too bad. Plus, the footprint of the machines was almost the size of a standard wave machine.” Being a high-mix assembler, Ayrshire needed flexibility. The company finally invested in a miniwave system that can easily switch from one program to another. “It’s not tied to one product line or niche,” Beard says. “It can do point-to-point when needed, or drag soldering and a mini wave for some larger areas if needed. The
Soldering nozzles come in various shapes and sizes to suit specific applications.
Programmability is particularly important for any machine in a high-mix assembly environment. Soldering software should provide a simple user interface and use scanned images or Gerber data.
www.assemblymag.com August 2009 / ASSE M B LY 35
Electronics Assembly
In some selective soldering systems, the board is held stationary, and the solder fountain moves beneath it. In others, the fountain remains stationary, and the board moves.
system is integrated in-line for complete automated assembly, and the best part is that the footprint is 3.5 feet by 4 feet.” After a short while, Ayrshire completely eliminated wave soldering on its assembly line. A standard wave soldering system produces a wave that is 18 to 24 inches wide, whereas most PCBs are much smaller. This means the machine is heating a lot of solder and producing a lot of dross unnecessarily, explains Beard.
With their smaller wave nozzles, selective soldering systems are much better suited for boards that are 4 inches wide. The system can accommodate boards that are more than 4 inches wide by moving them in a serpentine pattern over the wave. Soldering programs can be adjusted to optimize key parameters, such as speed, immersion depth, dwell time and temperature. The net result is that while the smaller wave nozzle solders
joints at a slightly slower rate than a traditional wave-soldering machine, it’s more efficient in the long run when maintenance, uptime, consumables and defect rates are factored in. “We specialize in low- to mediumvolume, high-mix, double-sided, surface-mount boards with maybe one or two through-hole parts on them,” says Beard. “Instead of using a wave solder [machine, which required] custom pallets or a masking step, our assemblies now go directly from the dispensing line to the selective soldering step and then on to various inspections.” Eliminating the wave soldering system saved Ayrshire approximately $120 per day in energy costs and eliminated some 3,500 pounds of dross. “The dross from selective soldering is only spoonfuls,” Beard says. Ayrshire also saved on labor. “When we went to selective soldering two and a half years ago, we had 16 people doing hand soldering during the first shift, eight people on the second shift, and four on the third,” Beard recalls. “Today, we are building the same volume and same mix of products, and we are down to six people on the day shift. That’s a manpower reduction of 75 percent.” Selective soldering has made a difference in defect rates, too, particularly with small boards for radio frequency applications. “[If there’s] a tiny icicle on a joint, all of a sudden you have an antenna and it throws off the whole board,” Beard says. “That’s where selective soldering really shines. It has cut our defects—bridging, damage to other parts, and so forth—down to virtually zero.” A For reprints of this article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.
ASSEMBLY ONLINE
Although the small nozzle solders joints at a slightly slower rate than a traditional wavesoldering machine, it’s more efficient in the long run when maintenance, consumables and defect rates are factored in. 36 ASSEMBLY / August 2009 www.assemblymag.com
For more information on soldering technology, visit www.assemblymag.com to read these articles: Three Boards in a Fountain. Soldering Soldiers. Step up to the Bar.
ASSEMBLY
ASSEMBLY EVENTS
Don’t Miss the Big Show Find the tools your company needs to succeed at ATExpo 2009.
As the economy makes its way out of the downturn, assemblers will need to work smarter and more efficiently than ever if they are to succeed in an increasingly competitive global marketplace.
By Adam Cort Senior Editor
D
espite the economic hard times, assemblers in the United States will still spend more than $2.5 billion on new assembly equipment this year, according to ASSEMBLY magazine’s 13th annual capital equipment spending report. Not only that, as the economy works its way out of the downturn, assemblers are going to have to work smarter and
more efficiently than ever if they are to succeed in an increasingly competitive global economy. To make sure your company has the capital equipment it needs to survive in this kind of environment, be sure and check out this year’s Assembly
Technology Expo (ATExpo), set for Sept. 22-24 at the Donald E. Stephens Convention Center in Rosemont, IL, immediately adjacent to Chicago’s O’Hare airport. As in 2008, ATExpo 2009, which is sponsored by ASSEMBLY magazine, will be co-located with the Medical Design & Manufacturing Midwest (MD&M Midwest) show and the Green Manufacturing Expo. Also co-located with this year’s ATExpo will be Quality Expo and the new Design & Manufacturing Midwest and Electronics Midwest shows. In addition, ATExpo 2009 will feature a range of conference sessions, including a quality track, a design track, a medical track, a green manufacturing track, and a track on automation and assembly. The latter, which is being sponsored and organized by ASSEMBLY magazine, will be comprised of a number of specialized sessions, including those on plastics assembly, affordable automation, lean manufacturing, compliant design, affordable robotics for smaller manufacturers, machine vision and recycling. (See sidebar, page 38.) Building the Future As it has been for more than a quarter century, ATExpo is the onestop source for assembly-related equipment and materials, including automated assembly systems, adhesive and solder dispensing machines, robots, conveyors, parts feeders, circuit board assembly equipment, adhesives and sealants, mechanical fasteners, machine
www.assemblymag.com August 2009 / ASSE M B LY 37
ASSEMBLY EVENTS
Prepare for the Rebound at the Assembly Conference As the economy gets back on its feet again, assemblers are going to have to work smarter and better than ever before to remain competitive. This, in turn, will require not only the latest technology, but new ways of thinking—both of which will be the focus of this year’s assembly conference at ATExpo. On Tuesday, Sept. 22, the conference kicks off with three tracks: “The Ultimate Plastics Assembly Seminar,” “Lean Manufacturing,” and “How to Profit from Automated Assembly.” The plastics assembly track will feature industry experts addressing everything from ultrasonic welding and light-cure adhesives, to the best ways of placing inserts and using the latest environmentally friendly materials. The track on lean manufacturing will include speakers such as Kevin Duggan, founder of The Institute for Operational Excellence, discussing how to employ lean techniques to grow a business in a recovering economy. The automation track will feature speakers such as Mikron Corp.’s Jim Mueller, who will explain how designing a new product with assembly in mind can reduce costs. On Wednesday, the conference continues with three more tracks: “Technology for Profitable Assembly,” “Robots and Vision,” and “Preparing for the Economic Recovery.” The session on profitable assembly will begin with presentations on resistance welding, crimp quality verification, and press fits and process monitoring. In the afternoon, the track continues with a panel discussion on how even small companies can benefit from robotics. There will also be a presentation by Denise Coogan, manager for safety and environmental compliance at Subaru of Indiana Automotive Inc., on how her plant has cut the amount of solid waste it generates to zero. The track on robots and vision will include sessions on robots and the “green” economy, collaborative robots working in close proximity to people, and how to employ machine vision to improve your bottom line. In the afternoon, Dr. John Kamauff, a
vision systems, power tools, presses, workstations, process monitoring systems, and test and inspection equipment. The show also plays host to dozens of integrators and machine builders with experience in assembling everything from the tiniest consumer gadgets to high-end medical devices and missioncritical components for the automotive and aerospace industries. This year’s ATExpo will include a number of what show organizer Canon Communications describes as technology-specific areas, including a sensors and vision area, a wire harness processing area and a new lean “factory,” which will feature lectures and a step-
principal and expert on supply chain management at Archstone Consulting, will give a pair of presentations titled “North America: the New Low Cost Manufacturer” and “Planning for the Rebound.” In these sessions, attendees will learn how companies can position themselves to take advantage of the latest trends in manufacturing. Finally, the conference will end on Thursday with a pair of workshops: “Reducing Part Counts and Product Costs Through Compliant Design” and “Lean Workshop: Operating System Design.” Chairing the session on complaint design will be Sridhar Kota, Ph.D., a professor of mechanical engineering at the University of Michigan. Leading the workshop on lean manufacturing will be Matt Zayko of the Lean Transformations Group. Individual sessions are about an hour long, and will begin at 9 a.m. and end at 3 p.m. on Tuesday and Wednesday. Thursday workshops will begin at 9 a.m. and finish at noon. For more information, including session abstracts and a complete conference schedule, go to www.devicelink.com/ expo/atexpo09/conference.html.
by-step demonstration on how to build an actual lean production area. Canon Communications is also creating an Innovation Briefs Theater, a 50-seat amphitheater complete with its own screen, where experts can give 30- to 40-minute seminars on various technologies. Co-Located Shows For those with responsibilities in the areas of design and planning, this year’s Design & Manufacturing Midwest show will include exhibitors featuring the latest in CAD, CAM and CAE software, computer hardware and peripherals, contract manufacturing services, linear motion devices, material handling
38 ASSEMBLY / August 2009 www.assemblymag.com
systems, plant engineering products, motors, drives and other manufacturing support equipment. Similarly, Electronics Midwest will be your one-stop source for the latest in component insertion and placement equipment, soldering machines and everything else you’ll need to manufacture and package printed circuit boards. For those either already a part of, or planning to become a part of the redhot medical-device industry, MD&M Midwest will bring together many of the major equipment, materials and service providers doing business in the Midwest and beyond. In fact, the five states comprising the
upper Midwest—Illinois, Wisconsin, Michigan, Indiana and Ohio—are already home to some 1,800 medical OEM facilities producing about $20 billion worth of medical devices and equipment every year. Thanks to the United States’ rapidly aging population and continuing advances in medical technology, those numbers will only get bigger in the coming years. Finally, for those looking to either become a part of the new green economy or cut their costs through environmentally friendly technologies, there is the Green Manufacturing Expo. Now in its second year, this event focuses on sustainable manufacturing and covers economically sound and nonpolluting manufacturing processes that conserve energy and natural resources. Products and services featured will include solar and wind power systems, recyclable and reusable packaging, energy management software, and consulting for energy management, recycling and waste treatment. Last but certainly not least, for those in search of the quickest possible return on investment for their trade show dollar, this year’s show will include an hourly “grab bag giveaway.” Every day of the show, between 10:30 a.m. and 3:30 p.m., there will be a drawing each hour, with prizes including MacBook Air laptops, Best Buy gift cards, iPhones, and iPod Nanos. Registration Information A single entry badge allows attendees to visit all six shows. If you preregister online or bring show material with you on-site, admission to the shows is free. Otherwise, you will be charged an expo-only fee of $55 to register on-site. Online registration is available even on show days. For more information, current exhibitor lists and to register for free show admission, visit any of the show web sites: www.atexpo.com, www. manufacturingweek.com, www. qualityexpo.com, www.mdmmidwest. com, www.greenmfgexpo.com and www.electronicsassemblyshow.com. A
Join Us at the Lean Factory!
Sponsored by the Lean Factory Group, comprised of Bosch Rexroth Corp., Orgatex Americas LLC, Leonardo Group Americas, and Omron STI, this year’s Lean Factory exhibit will demonstrate the importance of a data-driven approach to line design; the need to create an environment that supports lean with the right equipment
and infrastructure; and tools that can be used to create a visual factory. Attendees will see presentations on lean manufacturing; interact with experts in the field; and take part in the step-by-step creation of the perfect lean production environment, culminating in an actual build demonstration on an optimum lean line.
See us at ATExpo, Booth 1214 www.assemblymag.com August 2009 / ASSE M B LY 39
Products Grippers Certified for Clean Room Use Grippers are now certified for use in Class 5
Painting Robot Is Compact, Flexible The Paint Mate 200iA intelligent mini paint robot can be used to paint small parts and offers a cost-effective alternative in applications that would otherwise require multiple fixed paint guns. The system incorporates all the features of the popular LR Mate 200iC, including wrist load capacity, repeatability and speed. The robot is extremely flexible and can be mounted on the floor, on a tabletop, at an angle or inverted. FANUC Robotics America Inc. www.fanucrobotics.com 800-477-6268
Crimper Accommodates Multiple Stations clean rooms according to ISO 14644. Among the grippers now certified are PGN-plus parallel grippers, the DPG-plus sealed parallel gripper, the PZN-plus centric gripper, the DPZplus sealed centric gripper, the MPG miniature parallel gripper, the MPZ miniature centric gripper and the SRU rotary module. SCHUNK Inc. www.schunk.com 800-772-4865
The CrimpCenter 36 can accommodate up to six processing stations and is suitable for a use in a variety of applications employing cross sections from 24 to 12 AWG. Modern manufacturing materials and a number of new proprietary technologies allow for a compact, economic design without compromising quality. Proven state-of-the-art components provide outstanding output rates, while synchronized Ethernet powerlink ensures fast and continuous communication between software and servo drives. Schleuniger www.schleuniger-na.com 603-668-8117
Reactor H-VR Offers Adjustable Ratio Settings The Reactor H-VR is a simple-to-operate, variable-ratio dispensing system that can be
Test, Monitor System Easy to Configure The sigPOD PSV is an out-of-the-box, user configurable system that can be used to test or monitor virtually any operation during manufacturing, including press, torque, vibration, dispense and functional test. An easy-to-use setup interface allows operators to leverage an expansive library of processing and analysis tools. The system can be used on up to eight channels to allow for greater output without sacrificing quality. Sciemetric Instruments www.sciemetric.com 866-900-7054
Leak Detector Minimizes Operator Error used to process polyurethane foams and polyurea coatings. Designed for materials that have extreme differences in viscosity between their A and B components, the system allows end users to spray infinitely variable volumetric ratios ranging between 1:1 and 2.5:1. Maximum fluid output varies depending on the ratio setting. Graco Inc. www.graco.com 877-844-7226 40 ASSEMBLY / August 2009 www.assemblymag.com
MS-60Dry helium mass spectrometer leak detectors can be used to test the integrity of a wide variety of systems, containers and parts using helium as a tracer gas. The MS-60Dry is available with a standard 16 cfm Dry foreline-roughing pump for faster cycle times and use in clean room applications. The system’s software allows users to both locate and measure leaks with ease, at the same time minimizing operator error and maximizing throughput. VIC Leak Detection www.vicleakdetection.com 631-737-0900
Belt Conveyors Are Sturdier, Easy to Service
polyethylene. The fasteners are intended for one-time use and provide a cost effective means of creating a lightweight assembly. One size pin fits all lengths of posts. Posts are available in lengths from 1/2 inch to 1 1/4 inches. Micro Plastics Inc. www.microplastics.com 800-466-1467
TB belt conveyors feature sturdy aluminum covers to protect their chains and pinions. In
lower assembly costs. The adhesive is bright blue in its uncured state making it easy to see on the surface of substrates, in deep wells or when sandwiched between two layers of material. DYMAX Corp. www.dymax.com 877-396-2963 addition to providing superior protection, the covers make the conveyors easier to service because they require fewer locking screws. The conveyors are available in six different frame widths, from 60 to 250 millimeters, and can be ordered with either a single or double belt. The drive unit can be installed horizontally or vertically at any point along the entire length of the frame. Montech www.montech.com
System Handles Sensitive Materials The Dos A300 dispenser can be used to process everything from liquid, self-leveling
Microscope Records High-Speed Motion The VW-6000 motion analysis microscope is the world’s first microscope with high-speed magnified video-capture capabilities. The system can record up to 24,000 frames per second,
Robot Has ‘Zero’ Footprint
materials to abrasive resins. It is especially well suited to handling liquid and mediumviscosity polyurethanes, silicones and epoxies with or without filling materials. It can also be used for dispensing humidity-sensitive materials that need to be processed under vacuum. The system can be configured as a stand-alone manual workstation or as part of a larger production line. Scheugenpflug www.scheugenpflug.de
The new overhead-mounted RS3 SCARA robot is literally a “zero footprint” robot, saving assemblers valuable floor space. The system can be easily integrated into a compact assembly cell and offers 450 degrees of axis rotation for omni directional access. It comes standard with the low-cost, high-performance
making it possible to film moving targets that cannot be otherwise captured. Because it is small and portable, the system can be used on the factory floor as well as in the lab. Keyence Corp. of America www.keyence.com/vw
Mobile Workstation Safeguards Laptops This mobile laptop computer workstation provides a secure place to both store and use a laptop, at the same time positioning it at a com-
Posts, Pins Facilitate Light Assembly Micro PowerDrive RC180 controller to facilitate ease of use and reliability. EPSON Robots www.robots.epson.com 562-290-5910
New post-and-pin combination includes pins molded in white polycarbonate material and posts in various lengths molded in white
Adhesive Turns from Blue to Clear The 3-20794 See-Cure adhesive is a colorchanging material formulated with Ultra-Red fluorescing technology. It bonds to a variety of plastics and cures clear in less than a second when exposed to high-intensity UV light, enabling faster processing, greater output and
fortable work height. The station’s four largediameter swivel casters ensure easy rolling and maneuverability. The casters can be locked for greater safety and stability while working. The www.assemblymag.com August 2009 / ASSE M B LY 41
Products station provides a workspace that is 42 inches wide, 26 inches deep and 38 inches high. Custom dimensions are also available. Creform Corp. www.creform.com 800-839-8823
kit includes all necessary mounting hardware, making installation as simple as tightening down the bolts. GAM www.gamweb.com 888-GAM-7117
Slides Available in Five Days
Rails Provide Accuracy, Cost Savings
Customized LSK linear slide kits are now available in just five days, dramatically cutting lead times and reducing the overall cost of system assembly. The kits are compatible with any linear slide, belt or ball screw actuator, and any motor or gearbox. Standardized components are available for those applications requiring extra stiffness or dampening. Each
Sensors Combine Accuracy, Value The OD Value line of optical displacement sensors provides high-accuracy performance at a competitive price with a variety of interface capabilities for use in a wide range of
LFS 12 Series low-profile linear rails and car-
riages can be used in those applications that require low cost and accuracy, such as door enclosures and transfer systems. Each linear rail and carriage set employs a set of mating V-groove rollers. The standard rail length is 3 meters, but custom lengths are available. Techno Inc. www.technoautomation.com 800-819-3366
268 METRIC HINGES for a cleaner environment
quality control applications in the automotive, robotics and electronics-semiconductor industries. The sensors can measure targets regardless of color or reflectivity and include an easy-to-read bar graph display for fast installation and maintenance. SICK www.sickusa.com
Leak, Mass Flow and Electrical Testers starting at $2990.00
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Dispense, Spray System Includes Tilt Feature
Pipette Enables Contaminate-Free Dispensing
The Precisioncoat spray and dispense system now includes a programmable tilt and rotate feature, needle calibration and a vision system to help customers achieve maximum efficiency, flexibility and accuracy as they spray
The Stepper pipette enables contaminate-free dispensing in a simple-to-operate, handheld system. The dispenser incorporates a lightweight, ergonomic design and is constructed of aluminum for maximum durability. Users
three sizes and offers positive displacement dispensing in a range of volumes from 0.01 to 1.00 milliliter. Each pipette can dispense up to 100 shots per fill. Tridak www.tridak.com 860-626-6700
Readers Fill Multiple Niches HS-1 and HS-2D handheld readers provide out-of-box, plug-and-play performance and
and dispense coatings onto printed circuit assemblies and other devices and substrates. The programmable tilt and rotate feature, in particular, allows users the flexibility of five separate axes to coat alongside and underneath a wide variety of components. Specialty Coating Systems www.scscoatings.com
can dispense a variety of low- to mediumviscosity materials. The pipette is available in
can be plugged into a number of standard Microsoft Office programs, including Word and Excel. The HS-1 is lower-cost reader for use with linear barcodes, such as those found on printed black-and-white labels. The HS-2D reader is a higher performance model that can
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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.
Specializing in packaging adhesives and encapsulants in convenient syringe and cartridge systems, ideal of Electronic assembly. • Premixed and frozen two component • Difficult to package one component resins • Air-free syringes and cartridges for automated X-Y-Z dispensing systems • Maximum 5-day lead time from receipt of materials • Custom mixing and blending per your specifications
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5/6/09 10:14:19 AM Asb08094kit.indd 1
www.assemblymag.com August 2009 / ASSE M B7/9/09 LY 43 3:45:41 PM
Products be used to decode both linear barcodes and 2D symbols in a wide range of environments, including clean rooms. Microscan www.microscan.com
insulation residue as it is removed from the wires during stripping. Eraser Inc. www.eraser.com 315-454-3237
Wire Stripper Collects Insulation Residue
Robotic Cleaner Handles Heavier Loads
The Model DV1 twin-wheel wire stripper with integral dust collector can be used to strip magnet, enamel and film-insulated wires, as well as round, rectangular and square section wires with insulations such as Formvar, ML, Dayglass, Isonel and Polythermaleze. The system’s integral dust collection traps
Ecoclean flexible robotic cleaners can now accommodate industrial parts weighing up to
in the automotive and commercial vehicle industries. Dürr Ecoclean www.durr-ecoclean.com
TFT Systems Available with Hollow Shafts Torque Functional Test (TFT) systems providing monitored and measured amounts of torque during assembly and test operations are now available in a hollow shaft configuration. The new feature allows operators to access components with tools or sensors inserted through the center hole at the same time the
300 kilograms, thanks to a new conveyor component that reorients the parts being cleaned via a tilting station, thereby allowing the robot to handle heavier parts than in the past. The system is especially well suited to cleaning parts with complex geometries, like those
ELECTR C! • Electric Sheet Metal Handling & Work Holding • Fastt Delivery
VLB-900M Mini Locking Bit Comes With the Most Reliable Screwfeeding System on the Market. PLKE & PLCE E
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44 ASSEMBLY / August 2009 www.assemblymag.com
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components are being processed. The TFTs employ servomotors, precision position sensing feedback technology and extremely accurate torque transducers to produce controlled torque inputs and feedback monitoring. Promess Inc. www.promessinc.com 810-229-9334
Tubing Good for Appliances, Food Industry Ethelplas tubing is extruded from nontoxic, 100 percent virgin linear low-density Polyethylene resin for use in commercial and household appliances, the food industry and laboratory testing equipment. It provides good resistance to chemicals and is nonconductive. The tubing is available in nine different sizes, ranging from a 1/16-inch inner diameter to a 5/8-inch inner diameter. Ark-Plas Products Inc. www.ark-plas.com 870-453-2343
resistant to motor oils, transmission fluids and most other workrelated compounds, such as greases and cutting fluids. The stains can be applied by brushing, spraying or dipping. Dry time is less than 15 minutes. ITW www.dymon.com 800-443-9536
Laser Scanner Is Precise, Portable The SLP-500 3D laser scanning probe is a high-precision probe delivering virtually noise-free scan data for use in the automotive and aerospace industries. The system provides a laser line length of 50 millimeters and scans at very high speeds, making it ideal for use in scanning mid- to largesized objects, such as molds, stampings and sheet metal. The probes are portable and can be easily integrated with a coordinate measuring machine (CMM) arm. Laser Design Inc. www.laserdesign.com 952-884-9648
Applications include: small linear slides, medical equipment, instrumentation, packaging, material handling, rotary actuators and more
• High Energy Capacity in Minimum Sized Packages • Proven Designs & Performance • Ideal for Mounting in Confined Spaces • Self-Compensating & Adjustable Models
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Stains Are Environmentally Friendly
Farmington Hills, MI 48335 tel: 800-521-3320 fax: 248-476-2470 e-mail: [email protected]
DYKEM water-based stains can be used to permanently color code springs, small parts, tools and finished assemblies. The stains produce little odor and emit few VOC’s. Their non-xylene based formulation is
acecontrols.com
asb08094ace.indd 1
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See us at ATExpo, Booth 515 asb05094janome.indd 1
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www.assemblymag.com August 2009 / ASSE M B LY 45
Products Clamps Combine Accuracy, Ease of Use
wafer without leaving a mark, even when handling wafers that are smaller than the contact surface of the gripper. The gripper can also be safely used in a clean room environment. Schmalz Inc. www.vacuworld.comasb0809
Zero Point clamps offer ease of alignment, high-accuracy positioning and high clamping forces. They can be used with either hydraulic
or pneumatic actuation. Each clamp employs a series of balls that roll freely in a form-fitting ball channel that allows them to easily reposition themselves, allowing heavy fixtures to self-align easily. All components are made of stainless steel. Jergens Inc. www.jergensinc.com 800-537-4367
height, 5-inch-diameter casters and a choice of hanging drawers are also available. The benches come in light gray, bright blue or sand. Lista International Corp. www.listaintl.com 800-722-3020
Gantries Provide Speed, Precision AGS15000 series Cartesian gantries incorporate a planar design that minimizes dynamic pitch errors for use in a wide range of precision applications, including stencil cutting, fuel
Gripper Configured for Solar Production The new SWG vacuum gripper is configured for precise, gentle handling of highly sensitive wafers and solar cells. It provides a cycle time of 1 second and grips the entire surface of the cell manufacture, high-speed pick-and-place systems, automated assembly, dispensing and high-accuracy inspection. The system’s BLM and BLMH series brushless linear servomotors provide speeds of up to 3 mps and 5G acceleration. Aerotech www.aerotech.com 412-963-7470
Workbenches Are Sturdy, Economical The Arlink 7000 workbench is a cost-effective, easily assembled, general-purpose workbench capable of supporting up to 1,000 pounds. It is available with a range of work surfaces, including plastic laminate, static dissipative laminate and butcher block. Leg extenders for extra
Classified Need Work Benches
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For information on Classified Advertising call Vito Laudati: 630-694-4018 46 ASSEMBLY / August 2009 www.assemblymag.com
Advertisers Index Ace Controls ....................................................... 45
Promess ............................................................. IFC
AMSP All Metric Small Parts .......................... 42
Quality Bearings & Components .................... 12
Assembly Technology Expo 2009.................. 33
Robotic Industries Association ....................... 11
ATEQ .................................................................... 42
Saejong Industries ............................................. 43
Cincinnati Test Systems ................................... 27
Sankyo .................................................................. 24
Conductix-Wampfler.......................................... 32
Schleuniger Inc. .................................................. 10
DEPRAG Inc. ....................................................IBC
Schmidt Technology .............................................5
Dymax ................................................................... 25
Schunk Inc. .............................................................3
Edgewater Automation ..................................... 13
Sciemetric ...............................................................7
EFD ..........................................................................1
Sealant Equipment & Engineering ................. 39
Ellsworth Adhesives ...................................29, 43
Technifor ............................................................... 29
I & J Fisnar Inc. ...................................................BC
Techno .................................................................. 21
Janome Industrial Equipment USA Inc.......... 45
Techno Sommer ................................................. 12
Lista International Corp. ................................... 15
Turck ...................................................................... 28
PHD Inc................................................................ 44
Visumatic Industrial Products Inc. .................. 44
ProLine ....................................................................4
Weiss North America ........................................ 26
This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.
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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 9 (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 August 2009 / ASSE M B LY 47
Leading Lean Jamie Flinchbaugh Partner The Lean Learning Center Novi, MI
Close the Knowledge Gap
I
n the past two columns, I have used the A3 improvement process to explore some of the subtler but broad skill sets and mindsets of lean. A3 can be a helpful method to guide your thinking, and it enables greater collaboration and coaching. Last month, I focused on the imperative of good problem statements and the thinking that goes into them. This month, I move to the next quadrant of the A3, defining and clarifying the current condition. This section of an A3 can be populated with data, stories, pictures and anything else that helps explain the current condition. It should explain why you are getting the results that you are getting and where you must focus to make the required changes. But there is more to this section than simply cutting and pasting your favorite Excel chart. The underlying function of this quadrant is to drive learning and knowledge. Lean businesses constantly focus on generating new knowledge about how their processes and organizations really work. In this part of the A3 process, you should focus on that purpose. There are two fundamental questions that help in this process. The first is, what do I need to learn more about? Another way to phrase it would be, what specifically do I not understand in the areas where I need to gain knowledge? There’s no need to gather “new” knowledge about something you already
understand. The assumption is that there is something you don’t quite understand, so focus on exactly what that might be. This requires humility and curiosity. You must be willing to use what I consider one of the more powerful phrases a leader can use, “I don’t know.” And you must have the curiosity to invest time and energy in pursuit of that knowledge.
Close knowledge gaps before closing performance gaps.
48 ASSEMBLY / August 2009 www.assemblymag.com
The second fundamental question is, by what method can I learn this knowledge? There are many methods you may deploy. I have written more than once about the power of direct observation. Whenever you have to suspend your assumptions and trim your filters, you are more open to what is really going on. Going directly to the point of activity, whatever and wherever that is, can greatly expand your knowledge. There are other methods. You should deploy the simplest approach to gain the knowledge you need. The “5 Why” problem-solving method is a good example. In the “5 Why” method, you keep asking “why” about a condition until you get to the root cause. Invariably, you’ll hit the root cause by the
fifth time you ask “why.” The intent is not documentation or ensuring a particular rigor. It is a knowledge discovery process. That, I believe, is it’s real value. Developing and testing a hypothesis is also a good way to generate knowledge. Why bother? The fact is, you must close your knowledge gaps before you can close your performance gaps. Closing performance gaps where the knowledge is already clear and available is often simply a matter of execution. If you only need to execute what you already know, then the A3 won’t help you. The thinking process enables you to close performance gaps that are more challenging. To close those gaps, new knowledge, insight and maybe even wisdom are required. If you try to close the performance gap before you close the knowledge gap, you will ultimately end up back where you started. The second quadrant of the A3 is meant to capture the current condition. The ability to do this is found in those two key questions. What do I need to learn more about? And, how can I learn it? Keep these two questions in mind, and you will move forward with a high probability of success.
Email Jamie with comments via [email protected]. For his recommended books see tinyurl.com/leadinglean
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