IN THE NEWSPardon the Disruption!

Cincinnati Business CourierMarch 30, 2015

What is a disruptive technology? According to Clayton M. Christensen, a disruptive technology is a new emerging technology that unexpectedly displaces an established one. Christensen used this term for the first time in his 1997 best-selling book entitled “The Innovator’s Dilemma”. For example, the Internet of Things (or IoT for short) is a disruptive technology. It was a term coined by Kevin Ashton in 2009 and refers to uniquely identifiable objects and their virtual representations in an Internet-like structure. Equipping objects with identifying devices or machine-readable identifiers is a disruptive technology that is currently transforming machine monitoring.

Because of disruptive technologies, there are a number of advancements that are changing the way that manufacturers machine and produce parts. Four of these new technologies are:

1. Adaptive Machining

2. Minimum Quality Lubrication (MQL)

3. Machine-to-Machine Connectivity (M2M)

4. Digital Thread

Adaptive Machining employs in-process inspection to determine the shape and position of the workpiece that is to be machined, then adapts the CNC programming to machine the actual part with extremely high accuracy. It provides the capability to machine and blend complex 3-dimensional components and features automatically.

Currently, this new technology is having significant impact within the aerospace industry where expensive complex parts (such as turbine blades) are manufactured. This technology is best utilized with products that have extensive machining time in order to achieve the greatest impact.

The main goal of adaptive machining is to eliminate scrap and rework, stabilize the manufacturing process, maximize accuracy, and increase the profitability of the manufacturing operation.

MQL is the process of applying minute amounts of high quality lubricant directly to the cutting cool instead of using the traditional method of using substantial volumes of coolant to assist the cutting operations. MQL minimizes the environmental impact by reducing the fluid usage and the need for treatment and disposal.

Although the automotive industry is the primary industry using MQL for their machining processes, it is expected to filter down to other industries. If applied correctly, MQL may be a good solution for both low and high volume machining operations in a variety of industries while promoting a cleaner, safer manufacturing environment.

M2M refers to technologies that allow both wireless and wired systems to communicate with other devices of the same type and is considered an integral part of the Internet of Things (IoT).

IN THE NEWSTechSolve research and development consultants have taken a lead role in M2M technology research, using the MTConnect® standard that establishes an open and extensible channel of communication for interconnectivity between devices, equipment, and systems on manufacturing shop floors. The MTConnect® standard was developed by the MTConnect Institute, whose founding members include TechSolve, the Association for Manufacturing Technology (AMT), and GE. Standardization is considered one of the key ingredients for an accelerated deployment of the emerging “Internet of Everything” for the manufacturing industry.

TechSolve’s VizProductsTM (including ShopVizTM and VizAdapterTM) use the MTConnect® standard to provide the compatibility needed to gather data from a wide range of machining assets and production equipment – regardless of age or OEM – as well as sensors and human interface devices. This results in vastly more insightful machine monitoring that can return 20% improvement in productivity and utilization. Currently, only 3% of manufacturing equipment is monitored and there is a need for these types of applications that can help manufacturers make more informed decisions to increase capacity and reduce lead and cycle times.

Digital Thread is a concept that focuses on the total lifecycle of a product. In their Annex 1 titled TRANSFORMATIVE MANUFACTURING TECHNOLOGY: Manufacturing Technology Area 1, - Advanced Sensing, Control, and Platforms for Manufacturing Overview, The Advanced Manufacturing Partnership 2.0 (AMP2.0) stated that digital thread technologies offer the technical elements needed in smart manufacturing that is about enabling seamless interoperation of cyber and physical assets to increase productivity, product and process agility, environmental sustainability, energy and raw material usage, and safety performance.

The digital thread aims to ensure that the best materials, machine tools, and processes are communicated at each step of product development. This process creates an increase in first pass success which eliminates the costly trial and error process, and ultimately allows you to get the product to market faster and more efficiently. Errors and failures are even captured and reported back via feedback loops to prevent the same issues from arising again. Also, this better equips manufacturers to track a product from development of the first article through design and production to when the product is removed from service.

Manufacturers should take a realistic look at how these technologies will impact their business in an effort to become globally competitive and leaders in their industries. Three things that manufacturers can do to better leverage these technologies include:

5. Review and evaluate the data and utilization rates of their equipment.

6. Utilize external resources to help them better understand how these technologies will impact their business.

7. Educate and engage their workforce about these emerging technologies to eliminate fear and ensure successful implementation.

IN THE NEWS40 years ago something called Moore’s Law stated that processor speeds, or overall processing power for computers, doubles every two years. Comparatively, disruptive technologies may offer the opportunity to introduce smarter and faster ways to manufacture products even more quickly. Manufacturers who seek innovative ways to attain competitive advantage and adapt to emerging technologies and business models will increase their chance of thriving in both the local and global markets.

From the desk of Jeff Kamphake, Business Development Manager, and Brian Wilson, Buisness Development Manager