Manufacturing Technology

Hitachi’s Omika Works recognised as “Advanced 4th Industrial Revolution Lighthouse” by the WEF

Hitachi is first Japanese company to be listed. Hitachi Ltd. has announced that the Omika Works, which manufactures information control systems for social infrastructure systems and industries, was recognised by the World Economic Forum (WEF) as a Lighthouse advanced factory. The Omika Works is a factory showcasing Hitachi’s Lumada solutions which combines OT, IT and products. It has been solving issues and creating new businesses by mobilizing its technologies and expertise in a variety of fields leading to total optimisation and sophistication in the entire value chain which were recognised by WEF. The Omika Works is the first factory of a Japanese company to be recognized as a manufacturing Lighthouse. There were sessions for Lighthouse at the WEF Annual Meeting (the Davos Conference) held in Davos, Switzerland in January. Since 2018, the WEF has been recognising and announcing the most advanced factories that are world leaders in the adoption and integration of the cutting-edge technologies of the Fourth Industrial Revolution as Lighthouses. From the start of operations in 1969, the Omika Works has been providing information control systems for important social infrastructure systems, such as railway, electricity, water supply and sewerage. It has been engaged in the design, development and manufacturing of hardware and software as well as the maintenance and operation of customers’ systems. The Omika Works has expertise in high-mix, low-volume production tailored to the individual needs of customers. Onsite improvement activities has been pursued for years to achieve the mass customisation with productivity equivalent to mass production and the reliability required for mission-critical systems at the same time. The Omika Works was identified as a Lighthouse because of its years of efforts to contribute to the stable supply and operation of critical social infrastructure systems by achieving optimisation in the entire value chain ranging from the development […]

SmArtr app to reduce downtime for critical infrastructure

In line with Thailand’s transformation into a digital economy, global pump manufacturer Grundfos today announced the launch of its new cloud-based service app in Thailand to reduce downtime for key infrastructure in the country. The growth of consumer-centric apps reflects the country’s ambition for ‘Thailand 4.0’ – incorporating digitalisation in key processes to tackle common issues and challenges, which has already impacted sectors across banking, investment, telecom, broadcasting, e-commerce, logistics and tourism. In fact, 61 per cent of the Thai economy is projected to be ‘digitalised’ by 2022. Complementing these efforts, Grundfos’ newly launched mobile app, SmArt Serv, leverages digitalisation to enable the smooth operation of Thailand’s key infrastructure, ranging from industries to water utilities that use Grundfos products. The SmArt Serv app is designed to provide prompt and efficient service to resolve any issues with Grundfos pumps, reducing the service process and minimising the downtime on any repair. Grundfos pumps are used for various applications in Thailand, supporting key infrastructures such as airports, transport systems, commercial buildings including medical institutes and shopping complexes, and industries. These applications range from water distribution for consumers to water temperature regulation in air-conditioning in commercial buildings to wastewater management. Nicolai Thrane, Regional Service Director, Grundfos Asia Pacific Region, said: “With water playing such a crucial role in many aspects of Thailand’s public and private sectors, any downtime on critical infrastructure not only has a negative impact on business continuity and revenue, it also has far-reaching consequences when it comes to disruption in water supply.” “In line with Thailand’s new growth direction to become a high-income economy through technology and innovation, the SmArt Serv app is one of Grundfos’ many efforts to incorporate digitalisation with our service, ensuring a fast response rate and minimise any downtime for our customers as much as possible.” Through […]

CIMC Vehicles eyes emerging cold chain logistics

A few important policies have been released to support the ongoing development of the manufacturing industry. These, along with the deployment of policies in recent months by the People’s Bank of China, China Banking Regulatory Commission and other departments, help to guide the financial industry in increasing support for manufacturers. All signs show that these policies have somewhat favoured the overall profitability of the manufacturing industry. Among which, CIMC Vehicles (1839.HK), which has received much attention since its Initial Public Offering (“IPO”), has rallied much faster than many of its counterparts and continues to outperform the market. Looking at the segmented fields of the semi-trailer industry, we draw attention to the growth prospects of the cold chain logistics industry. Since 2014, China’s cold chain industry has experienced a period of rapid development. According to the China Cold Chain Logistics Development Report (2019), the growth rate of China’s cold chain logistics increased from 19% in 2014 to 20.3% in 2018. The annual growth rate of circulation services and related equipment introduced by cold chain logistics has exceeded 30%. With the improvement of China’s economy, the continued trend toward urbanisation and the implementation of a series of promotional policies for consumption upgrades and domestic consumption expansion, it is expected that the total volume of China’s cold chain logistics will continue to increase. The report also pointed out that the total amount of cold chain logistics in 2018 accounted for only 1.7% of total social logistics, which is still far off the numbers being registered in developed countries, suggesting that the industry is still in its early stages of development. With the development of cold chain logistics towards warehouse integration and logistics automation, the research and development (“R&D”) as well as production of cold cars and core components for cold car demand has […]

Rockwell Automation saves with new servo system

The growing consumer desire for more product variety and packaging sizes is creating a need for smaller, more flexible machines. To provide a more cost-effective option for OEMs building smaller machines, Rockwell Automation is introducing a new Kinetix 5100 servo drive, Kinetix TLP motor and cable that can function as a system without a controller. The Allen-Bradley Kinetix 5100 servo drive has multiple control modes available to support a wider range of high-speed, low-power motion control applications. The drive can be used with a Micro800 controller, a Logix controller or even by itself, allowing OEMs to choose how the product best functions in their applications. “The Kinetix 5100 servo system works especially well for small- to mid-sized packaging machines that need cost-effective servo control,” said Simon Wong, product manager, Rockwell Automation. “Bundling the drive, motor and cable together creates more competitive system pricing. And the ability for OEMs to select the products based on a machine’s power ratings can save time and effort – and help them get to market faster. This approach and product portfolio positions Rockwell Automation to accelerate our growth in China and emerging markets.” The Kinetix 5100 servo system can also help OEMs make customers more productive. With the explosion of SKUs, manufacturers are faced with multiple changeovers, which are often a manual process. Using the Kinetix 5100 servo drive, OEMs can create a motorized, or automated, system that can help speed up changeovers. Additionally, with built-in safe torque off, users can remove motor torque without removing power from an entire machine, allowing a machine to restart faster after it has reached a safe state. Dual-port EtherNet/IP also supports device-level ring topologies. The Kinetix 5100 servo drive provides an easy migration option for users of the Allen-Bradley Ultra 3000 digital servo drive. That system will soon […]

Siemens expands additive manufacturing portfolio through acquisition of Atlas 3D

Atlas 3D helps designers define optimal part orientations for ‘right first time’ 3D printing Cloud-based, GPU-accelerated Sunata software can reduce downstream 3D printing errors caused by thermal distortion up to one hundred times faster than other solutions on the market Siemens announced today that it has signed an agreement to acquire Atlas 3D, Inc., a Plymouth, Indiana-based developer of software that works with direct metal laser sintering (DMLS) printers to automatically provide design engineers with the optimal print orientation and requisite support structures for additive parts in near real-time. Atlas 3D will join Siemens Digital Industries Software, where its solutions will expand additive manufacturing capabilities in the Xcelerator portfolio of software. Sunata software uses thermal distortion analysis to provide a simple, automated way to optimise part build orientation and generate support structures. This approach allows the designer—rather than the analyst—to perform these simulations, thereby reducing the downstream analysis that needs to be conducted via Simcenter software to achieve a part that meets design requirements. Siemens plans to make the Atlas 3D solution available through its online Additive Manufacturing Network. “We welcome Atlas 3D to the Siemens community as the newest member of our additive manufacturing team. Our solutions industrialize additive manufacturing for large enterprises, 3D printing service bureaus, design firms and CAD designers,” said Zvi Feuer, Senior Vice President, Manufacturing Engineering Software of Siemens Digital Industries Software. “The cloud-based Sunata software makes it easy for designers to determine the optimal way to 3D print parts for high quality and repeatability. The combination of Sunata with the robust CAE additive manufacturing tools in Simcenter enables a ‘right first time’ approach for industrial 3D printing.” “Siemens is a leader in additive manufacturing, with the most integrated and functionally robust solutions in the industry, so we are excited to join the team,” said […]

Flange facing machines deliver fast and accurate performance

Enerpac Mirage OD mount flange facing machine Enerpac is introducing a new range of external mount flange facing machines designed for fast installation and accurate machining of large diameter flanges used in applications throughout Australia, New Zealand and Papua New Guinea. The new Mirage branded OD mount facers are the perfect choice for machining flanges 30” to 80” (762-2032mm) diameter in industries such as oil and gas plant, offshore platforms, refineries, LNG, pipe spool, heavy industrial fabrication, shipbuilders, EPC contractors, industrial plant, power plants, service and maintenance, says Enerpac Channel and Product Leader – Australasia, Mr Andrew Marsh. Applications also include facing heat exchanger flanges, maintenance projects, large flanges such as crane pedestals and flanges where bore mounting is not preferred. “The simple Outside Diameter (OD) mount configuration of the new machines overcomes industry reluctance to bolt ID mount flange facers to the inside of heat exchanger tubes,” says Mr Marsh. Each of the 6 machines in the range includes a continuous variable auto-feed which enables on-site machinists to create a wide range of gramophone-surface finishes to ASME standards (regulating the design and construction of boilers and pressure vessels). Robust construction and the inclusion of heavy-duty bearings ensure all machines deliver high metal removal rates whilst delivering accurate results. Easier and quicker machining “These new products provide all of the versatility to carry out different flange facing projects you’d expect from an Enerpac product, but, when used for heat exchanger refurbishment, they go a step further. “Convenience for the user has been taken to the next level by providing the clever ability to attach milling rails while the machine is still mounted in-situ,” says Mr Marsh. This innovative feature makes it easier and quicker to machine heat exchanger division slots. Machining the back face of flanges can also be carried […]

See and solve failures before they happen with predictive analytics

Wouldn’t it be nice to know when the devices in your home are on their last legs, so you could fix or replace them before they break? Just imagine how much better life would be. No more air conditioner breakdowns in the dog days of summer. No more unusable dishwashers on busy weeknights. No more computer crashes before you can back up your family photos and personal files. The same holds true for the plant floor. By knowing when machines and equipment are about to fail, you can proactively service them to avoid stressful situations like downtime, missed customer orders and quality issues. We may not know when our home technologies will be kaput. But such insights are possible in your production operations today using dashboards with predictive analytics. When real time is too late From smart machines to connected sensors, IoT technologies have forever changed how you see your operations. You can now access data and analytics that matter to monitor almost any aspect of production, in real time, around the clock. This data is great for tracking performance, quality and more. Real-time data is not enough, however, when it comes to spotting machine or equipment failures that cause unexpected downtime. You need insights into potential issues before they cause downtime, not after. This is where advanced analytics software and dashboards come into play. The software combines real-time data with machine learning to understand the patterns that precede downtime events and other issues. It’s presented in a dashboard and can detect anomalies that may indicate new failure modes or other issues that need to be investigated. These predictive insights can help your workers solve any number of challenges in your operations. Look into your future Even more valuable than knowing when something is about to fail is knowing what you need to do […]

OnRobot takes robot compatibility to the next level

New Digital I/O Converter Kit and Quick Changer for OnRobot end-of-arm tooling (EoAT) dramatically simplifies automation with a single platform for a full range of collaborative and light industrial robotic systems. OnRobot, a global leader in end-of-arm tooling (EoAT) for collaborative robot applications, has introduced two new products – the Digital I/O Converter Kit and Quick Changer – which together with other OnRobot EoATs, creates a unique One-System Solution that dramatically simplifies automation. OnRobot’s Digital I/O Converter Kit allows OnRobot EoATs to work with a full range of leading collaborative and light industrial robot brands. Building on that initiative, all OnRobot products now have a unified mechanical and communications interface based on the OnRobot Quick Changer, which is now an integrated part of all OnRobot products. An additional Dual Quick Changer incorporates these same new capabilities while allowing the use of two tools in one cycle, mixing and matching to suit application needs and maximising robot utilisation. Now, with a single robotic system, single platform for programming and training, and single vendor relationship, manufacturers have access to a full range of tools, full robot compatibility, and virtually unlimited possibilities for collaborative applications. This new one-system solution speeds deployment so manufacturers save time and money and can quickly realise the benefits of automation. Manufacturers are demanding more from their robotic applications, and end-of-arm tooling has become the key to optimising their investments. This integration of the Quick Changer across the current product lineup makes it easier than ever to switch between tools and robot types, allowing flexibility and reducing downtime for more efficient production and faster automation ROI. This is another step closer to a unified OnRobot one-system solution that makes it easy, fast and cost-effective for manufacturers to build collaborative applications, no matter which robots they choose.” Unified platform across […]

The plural of plastic

-Natalie Martin, 3R Material Innovation Manager Plastic is a hot topic around the world these days, and so it should be. The terrible effects it has on the environment are undeniable, and there is evidence those effects are circling back to us. Plastic has also become something of the posterchild for society’s conspicuous over-consumption. But is plastic all bad? The short answer is actually, no. Plastic – first developed by British inventor Alexander Parkes in the early 1860s – was hailed as something of a miracle substance. Light, durable, easy to sterilise, cheap to make – the list of positive properties is impressive. Without plastic the world would be a very different place than it is today – simply consider how many things are made, at least in part, of plastic. It’s probably easier to think of how many things are not. It is of course some of those very same properties – namely its durability – which have made plastic an environmental disaster. Combine this with a single-use, throw away culture around plastic and there is a serious problem. But plastic is recyclable, isn’t it? Well it is, and it isn’t. This is because one of the biggest issues is plastic isn’t just one substance – it is in fact a complicated web of different types and grades, each with different properties and applications. Broadly speaking plastics fall into two groups – thermoplastics, which can be remoulded with heat, and thermoset which cannot and need other processes, such as the use of chemicals. The most commonly used plastics have been assigned identification numbers which identifies the plastic types. These range from 1 to 7 with category 7 being the ‘all other’ or mixed plastics. This is where recycling becomes complicated. As you might imagine thermoplastics are easier to recycle […]

Software framework generates ISO programs for CNC machine tools

A powerful new software framework tool enables users of CNC machine tools to generate and test ISO part programs offline. The tool looks set to win across-the-board approval in busy machine shops, where an uninterrupted workflow can provide a key productivity advantage. Flexium Office framework software runs under Windows 7/8 or 10 on any standard PC. It allows any of NUM’s technology HMIs (Human-Machine Interfaces) to be used for specific projects – without requiring access to the target CNC machine tool. The corresponding ISO part program can be created offline and can also then be tested offline using NUM’s Flexium 3D simulation software, before being transferred to the target machine. Application-specific technology HMIs form part of the company’s Flexium CAM (Computer-Aided Manufacturing) software suite. The HMIs cover every type of CNC machining operation, including hobbing, shaping, milling, threaded wheel grinding and cylindrical grinding. After selecting the most appropriate technology HMI for the task, the user simply carries out basic data definition tasks for the project in hand, using the highly intuitive tools and workflow commands provided by Flexium Office. Multiple projects can be started and saved at any time – allowing collaborative team development if desired – and the framework software provides support for 14 languages. As soon as the user is satisfied with the process and workflow of a project it can be used to generate the corresponding CNC part program – entirely automatically. The CNC program can either be transferred directly to a nominated machine in the production plant, usually via a TCP/IP network, or input to NUM’s Flexium 3D simulation software for thorough evaluation before being issued for production purposes. The key advantage of simulation is that it enables users to optimise any ISO-code part program offline, further helping to maximise productivity by leaving the CNC machine […]

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