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Addressing the six biggest losses in manufacturing

-Rob Stummer, APAC CEO,SYSPRO As the manufacturing sector continues to navigate chinks in the global supply chain while trying to meet customer demand in a COVID era of restrictions, the fact remains that manufacturing is an industry that the pandemic has put under the spotlight and one which continues to be more competitive than ever. For manufacturing organisations, the priority remains on reducing waste, being more efficient and continuing to have a competitive edge over others. Being able to identify what is referred to as the six big losses will provide businesses with an equipment-based perspective on lost production time that they can use as part of their improvement program. Some manufacturers have implemented programs like Total Productive Maintenance (TPM) and focused on improving Overall Equipment Effectiveness (OEE) with the aim of streamlining manufacturing processes and increasing output. While TPM is an equipment maintenance model that aims to achieve perfect production with no breakdowns, slow running or any other machine related problem that affects throughput. OEE is a metric that measures how well the machine is being utilised, otherwise known as uptime, the speed of the machine and the quality of the production. In the past, due to legacy Operational Technology (OT) systems, manufacturers had no clear visibility into the manufacturing process and could not always tell where equipment bottlenecks were. OEE supports TPM based initiatives by measuring progress towards the nirvana of perfect production and one of the most effective ways of improving OEE is to identify the six big losses. 1. Equipment failure Equipment defects and failures result in downtime, financial impact, inventory discrepancies and poor quality-control. This situation can occur for several reasons and can be because of unplanned downtime, no available operators and a lack of raw materials. When equipment is scheduled for production but is not running for any significant period due to a failure of some sort, it is categorised as equipment failure and is an availability loss. A simpler way to think of […]

Value technical staff and be considered competitive

-Alistair Gordon Technical specialists such as engineers, software developers, scientists or economists are expensive to hire and require great effort to retain. And despite the expense and effort, often they don’t create the value or innovation that business owners expect. Our organisation has been coaching technical specialists for 10 years. I am still surprised by how much money is spent on the hire of technical specialists, and once they are hired, how little attention is paid to their performance. In an organisation that takes a “hire and forget” approach to these specialist roles, innovation is challenging, not least because the process to pitch and adopt new ideas will be long, impractical, and frustratingly opaque. On one side, specialists don’t know how to pitch, network or commercialise ideas. On the executive side, ideas that aren’t well pitched, with clear commercial benefit, are blocked before they get anywhere near the executive suite. Want to improve competitiveness in an organisation? Challenge each of its experts to master broader business effectiveness, not just technical expertise – to become a “master expert”. But to make innovation reliable and consistent, organisations must reframe their goals for specialist training, development, manager expectations, expert career paths and appraisals, with all supporting the goal of mastery. Experts don’t have their commercial skills developed, but they should Why such a radical change? It’s because experts, to date, have not had the development they need. Consider the career of a manager – not a technical specialist, but a high-performing people leader. They are appraised and promoted on their ability to achieve commercial goals, to communicate strategy and manage upward. From the first days of their career, their development, career ladder, appraisals, and mentoring all challenge them to master business and relationship skills. In other words, they are trained and supported to […]

Drawing software simplifies 2D path design for users of CNC cutting machines

A unique 2D drawing tool simplifies the design and creation of executable G-code files for CNC cutting machines. Known as NUMcad, the new drawing software runs directly from the machine’s operator panel and also under Windows on any standard PC. Its user interface mimics that of many popular CAD packages and is highly intuitive, making it ideal for people with minimal design experience. NUMcad is suitable for both design origination and design modification. Simple drawing tools are provided for functions such as Line, Polyline, Arc 2P and Arc Center-Radius; and they are backed by a suite of editing tools such as Meet Two Lines, Shrink or Extend – and even Insert Micro-joint – which enables users to very easily customise and modify shapes. If a user already has a CAD file and wishes to modify it, NUMcad allows AutoCad DXF files to be imported. And in the event that the user does not have a DXF file, but has created the shape on the CNC cutting machine itself, NUMcad also allows this shape to be imported from their customisable parametric shapes library. The NUMcad software package includes a post processor; shapes or patterns that have been drawn or imported can be automatically converted into an executable G-code file for the CNC cutting machine. Using NUMcad, each segment of a cut can be set to rapid, marking, rough, medium or fine cut qualities, to achieve the user’s desired finish; the properties associated with the cut type are pulled from a Technology Table. Both standard shape and custom fly cutting functionalities are available, and associated functions include the ability to control the cut-side placement (kerf compensation) and tilt angle of the machine’s cutting nozzle. Nesting gives the user the option to create complex paths containing the same pattern. With settings like nesting […]

Skills needed for the green jobs of the future

Farming, architecture, science and teaching are some of the sectors that will need new green skills, according to the United Nations Environment Programme. Almost half of young people feel they don’t have the right skills, according to the World Economic Forum’s Davos Labs Youth Recovery Plan 2021. In the World Economic Forum’s Future of Jobs Report 2020, employers estimate that four in 10 workers will need to be reskilled. Making smart decisions today could set up the world’s young people for success in the green jobs of tomorrow. But shaping those decisions can be tricky as many of those future jobs don’t yet exist. The United Nations Environment Programme has stepped in with a helping hand in the shape of GEO-6 for Youth – a digital guide on sustainable career choices and the skills required to thrive in green industries. Here are six key skill categories that can help you build a successful career in the future. The green economy will need young people with a range of different skills. Image: GEO-6 for Youth, UN Environment Programme Science skills: The green economy of the future will be heavily reliant on workers with a strong science background. Key roles will include environmental scientists, biologists, hydrologists and biochemists. People in these jobs will monitor, manage and protect natural resources including land and valuable water supplies. Architectural and planning skills: Buildings will become more energy efficient, with fewer resources used to construct and operate them. Architects and planners will design these buildings to comply with environmental regulations and client demands for green spaces. Green engineering and tech skills: Today’s young people will be tomorrow’s green engineers, helping to design and maintain solar panels, wind turbines, low emissions vehicles and other green economy technology. Agriculture skills: As farming and food supply becomes more sustainable, there’ll be […]

Choosing the right robotic solution for every application

Though industrial robots have their individual strengths, manufacturers should consider the requirements of their application before deciding which to purchase. The payload, stroke length, precision and flexibility needed will all influence whether a linear or articulated robot is the right choice. The existing infrastructure should also be a factor, and which type of robot would integrate more effectively. Three of the most popular robot types are Cartesian, six-axis and SCARA robots. Cartesian Robots Cartesian robots are a common choice in industrial applications. They operate by moving along three orthogonal axes using the Cartesian Coordinate system. They are also known as linear robots, as they move in a straight line along a support frame, rather than rotating. Cartesian robots do not offer as much in terms of flexibility as articulated robots. They are an excellent choice for processes that require strength and reliability, but for applications requiring more degrees of freedom, an articulated robot may be more suitable. The rectangular work envelope on a Cartesian robot means that more of its footprint is active workspace, with no ‘dead zone’. This is more circular in a six-axis robot, meaning that there is more dead space, but the larger number of axes allows more range in the types of movement that can be done. The footprint of a Cartesian robot is well defined and thus can be easily integrated into existing infrastructure. They may require a lot of space to install and run but can be mounted overhead or on walls depending on the size, saving space on the ground floor. Speed is another important factor to consider — speed impacts cycle times, so the speed capabilities of the robot should fit manufacturer requirements in terms of productivity and output. Cartesian robots are a great choice for processes requiring high speed and fast […]

With Cintoo Cloud work more efficiently

Cintoo Cloud continues to bridge the gap between Reality Capture and Digital Twins as it hits one million laser scans uploaded to its platform, demonstrating the demand from businesses for cloud-based technology to drive more efficient and collaborative ways of working. Industry 4.0 organisations are recognising the time, resource and cost savings to be gained by basing their Digital Twins of existing assets on meaningful, trustful Reality Capture data, which they can glean from the platform by uploading their laser scan data and BIM and CAD models. With a client base spanning utilities, oil and gas, energy, automotive, water treatment, food and beverage, construction, engineering, architecture and cultural heritage, the platform’s 12,000 users have uploaded more than 10,000 BIM models and 200 million square metres of laser scans – the equivalent of twice the surface area of Paris – to Cintoo Cloud. Companies are also leveraging their Reality Capture data in the platform for QA/QC and construction progress monitoring, scan-to-BIM, asset management, retrofits, predictive maintenance, decommissioning and much more. A SaaS platform, Cintoo Cloud turns massive laser scan data into cloud and BIM compatible Reality Data that can be shared, viewed, annotated, measured or distributed for collaborative Scan-to-BIM and Scan-to-CAD workflows. It also enables asset management and as-built versus model comparisons. The platform leverages a unique point cloud-to-mesh technology, allowing for fast streaming of high-resolution, mesh-based scan data in a web browser with no plug-in to install. Leveraging Cintoo SDK and APIs, mesh-based streaming can also be used to build VR and AR apps, mixing scans and BIM or CAD in the Unreal and Unity platforms. The platform has rapidly growing audiences in Australasia, and is being used to host and manage the laser scan data of teams working on a diverse range of projects such as automotive factories in Detroit, Michigan; North Sea oil rigs; the renovation of the Howard Middle School in Atlanta – Martin Luther King Jr’s former school; and cultural heritage sites such as the ancient city of Volterra in Italy. Businesses struggling to share, view or distribute massive as-built laser scan data to teams, contractors […]

Surf Loch creates the perfect wave

Surf Loch has been developing wave-making technology since the 1980s, and is using software from Siemens’ Xcelerator portfolio and automation technology to create wave pools that deliver ocean-quality waves which can be tailored to each individual surfer. By combining the digital and real worlds in a comprehensive digital twin, Surf Loch has been able to master the creation of custom waves through software simulations, before building and testing in a physical facility. This has enabled Surf Loch to deliver waves that match the needs of the surfer and produce them consistently and reliably according to their individual skill level. In addition to its software solutions, Surf Loch leverages other parts of Siemens’ Digital Enterprise portfolio, such as automation and drive technology, to optimize their surf pools. “When we make a wave, we’re controlling every aspect of how that wave gets formed, to the 1000th of a second,” said Tom Lochtefeld, founder and CEO of Surf Loch. “Working with Siemens gives us the unique ability to connect the real and digital worlds to achieve that level of precision. By embracing this kind of digital mindset, we can provide surfers with 400 waves an hour; in the ocean, the average surfer would be lucky to get five.” Surf Loch’s vision is to make the sport accessible to anyone anywhere while not compromising on the unique ocean experience. As surfing continues to increase in global popularity, Surf Loch aims to attract and serve more surfers in their pools to reduce the overall human impact on natural beaches. Surf Loch uses a range of solutions from the Xcelerator portfolio to create different wave variances while still ensuring they feel like surfing on the ocean. The team creates a digital twin of the wave, and then uses computational fluid dynamics (CFD) analysis and multidisciplinary optimisation […]

Raising the bar for automated microchip testing

esmo group a full-service systems integrator that provides innovative and advanced engineering services — has rolled out upgrades and additional features for the talos 2021 system. First launched in 2019, the talos engineering handler is a reliable and easy-to-use handling system for semiconductor test applications, and is esmo’s solution to the industry’s need to cost-effectively test increasingly compact and complex devices within a shorter period of time. At the core of the talos engineer handler is its state-of-the-art active thermal control system (ATC), which allows manufacturers to carry out multiple test temperature cycles and achieve the highest temperature accuracy. The talos engineering handler provides semiconductor companies with the most stringent quality control and assurance, ensuring products are tested to specification. A highly flexible and cost-effective test system, the talos platform helps manufacturers achieve faster time-to-yield with higher overall equipment efficiency. Furthermore, its remote control and monitoring feature allows businesses to remotely manage and conduct device handling. The talos system supports the testing of devices with any site pitch dimension, which allows semiconductor companies to use already existing production load boards and sockets seamlessly. Its tray or tube loading and unloading feature also makes it possible for manufacturers to run the talos system in a mixed media operation. As such, loading trays, tubes, and tapes can be combined with their unloading counterparts, and devices can even be sorted from one media to another, such as from tube to tray. Designed to meet both test and production floor requirements, the talos handling system features a highly accurate pick-and-place robot system and a standard docking interface that is compatible with all testers. The talos can also be employed as a basic, kit-less test handler, or as an advanced test handling system with its expansive selection of optional modules. Key features of the talos: […]

Supertec chooses NUM technology for its CNC cylindrical grinding machines

Supertec Machinery Inc., one of Taiwan’s leading machine tool manufacturers, has chosen to base new versions of its renowned Plunge type of CNC cylindrical grinding machines on NUM’s Flexium+ CNC platform. Founded in 1954, Supertec Machinery Inc. has grown to become one of Taiwan’s top machine tool manufacturers. The company specialises in precision grinding automation and produces a diverse range of centreless, cylindrical and surface grinding machines. Based in Taichung City, Supertec operates sales and support facilities at strategic locations throughout Asia and Europe, as well as in the USA and South America. Supertec has traditionally used Fanuc CNC systems for most of its machine tools. However, when NUM added non-circular grinding functionality to its popular NUMgrind cylindrical grinding software back in June 2020, the company realised that this innovative CNC technology provided exactly what many of its customers needed on their cylindrical grinders. NUMgrind simplifies the creation of G code programs for CNC grinding machines through the use of a highly intuitive graphical human machine interface (HMI), and unlike conventional CAD/CAM workstation tools, it is designed specifically for use by shop floor personnel in a production environment. After evaluating the software, Supertec immediately raised a purchase contract with NUM. According to Betty Chu, Supertec’s Assistant General Manager, “NUM has an excellent reputation in the grinding industry. Much like Supertec, this has been earned over many years. And the latest version of NUMgrind, which accommodates non-circular grinding, is a natural fit for our CNC cylindrical grinding machines. We also now benefit from very responsive local support – NUM’s Taiwan facility is less than 15 km away from our factory.” Supertec’s Plunge type of CNC cylindrical grinding machines offer a choice of six capacities, covering distances between centres from 500 mm to 2,000 mm. The machines can also accommodate grinding diameters from 300 […]

FARO introduces BuildIT 2021 Software Suite

FARO), a global leader for 3D measurement, imaging and realisation solutions, has released its most advanced BuildIT 2021 software suite, which represents the next evolution of this platform that simplifies workflows, improves performance and enhances ease of use. BuildIT offers three individual products – BuildIT Metrology, BuildIT Projector and BuildIT Construction – each designed to address the most challenging quality inspection, manufacturing and assembly or construction issues, offering the most flexible and intuitive user interfaces in their respective applications. While the BuildIT 2021 suite is integrated with FARO hardware products to ensure a best-in-class FARO solution experience, it also delivers high-quality outcomes for non-FARO hardware products. “The performance enhancements in BuildIT 2021 Software Suite are substantial,” said Vito Marone, FARO Senior Director of Software Product Marketing. “For example, by using this significant upgrade of our BuildIT Construction software, users can complete reports in five minutes or less – a process which used to take 10 minutes or more.” BuildIT Metrology 2021 features upgrades related to four key areas, including: user experience, probing, scanning and automation: Inspection annotations – Can now be defined prior to perform any measurement and then computed and populated dynamically as new measurements are added; dynamic annotations are supported for points, lines and curves, and surfaces FARO Laser Tracker Improvements – Integrates the latest SDK (software development kit) to provide a more seamless Wi-Fi experience by handling disconnections and reconnections automatically Improved GD&T (geometric distancing & tolerancing) – Runout and total runout tolerances are now supported with any DRF file extension that frees DoF (degrees of freedom) required for a proper evaluation of tolerances Faster alignment and analyses – By trading a few microns in accuracy, the alignments and analyses gets a boost in speed between 10X to 100X Auto-complete and syntax highlighting – Are now available […]

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