The operational wish list: what manufacturing people would really like. (Produce).

WE ASK SOME OF THE PEOPLE WHO ARE ACTUALLY INVOLVED IN PRODUCING PRODUCTS WHAT THEY WOULD LIKE TECHNOLOGY VENDORS TO PROVIDE, SOME OF THEIR ANSWERS ARE SURPRISING. ALL OF THEIR ANSWERS OUGHT TO BE ADDRESSED BY SOME ENTERPRISING ORGANIZATIONS.

Next month, the 2002 rendition of the International Manufacturing Technology Show (IMTS) will be held by the Association for Manufacturing Technology (AMT) in Chicago's McCormick Place from September 4-11. In all, there will be some 1,300 exhibitors showing the latest equipment, systems and accessories in an area measuring 1.3-million [ft.sup.2]. To provide attendees with a better sense of what's where, there will be specific areas called "pavilions."

The nine pavilions for this event are: Metal-cutting; Machinery Components/Cleaning/Environmental; Controls and CAD/CAM; Gear Generation; EDM; Quality Assurance; Tooling and Work-holding Systems; Metalforming and Lasers; Business Services; Abrasive Finishing/Sawing/Finishing. And for those who are more interested in learning about the trends and developments in the manufacturing arena (from equipment to strategies), the Society of Manufacturing Engineers, in cooperation with AMT, is hosting a concurrent manufacturing conference. You can learn all about this by going to www.imtsnet.org.

What will be exhibited at IMTS 2002 is what product vendors have developed to address customer needs. But what about the needs that seem not to be addressed? What about the things that people in industry are really interested in? What if there was a proverbial magic wand that could be waved? What would people really want?

As we were wondering about that "If you could have anything, what would it be?" question, we put it to some of the leading manufacturers in the industry. What we discovered is that while some people may think that "manufacturing" people are solely interested in things that cut or form metal or plastic, or things that screw or otherwise put things together, their actual areas of interest are significantly broader.

SMALL. EVEN ATOMIC SCALE. For example, consider Dennis M. White, plant manager of Continental Teves Braking Systems operation in Morganton, NC. He's looking for: "Programmable read/write transponder tags that can be used for such things as traceability, information storage, serialization, and the like. Yes, there are transponder tags, but not of the sort that White is looking for: ultra small, so small that they could be added to raw materials and customized after product fabrication. One more thing: inexpensive. A fraction of a cent.

* No more blueprints. He'd like to see a good 3D concept. Two points: he means no more blueprints, anywhere. And he wants this replacement concept to be universally deployed.

* A process that replaces traditional machining operations by separating materials at the atomic level. This would be directed by the aforementioned 3D model.

* And not only is he interested in something that separates at the atomic level, but a rapid material deposition process to build specifically tailored parts in minutes.

* A vision system/robotic combination that would allow all assembly operations to be performed automatically.

SMARTER & MORE FLEXIBLE.

Steve Ballenger, vice president, Operations, Chassis Div. of Robert Bosch Corp., who has responsibility for 10 plants in the U.S. and Mexico that manufacture brake components, is looking for some advances that are somewhat nearer term. Ballenger is seeking "Machine tools designed and delivered with 'adaptive learning,' and which, in all cases, are electronically linked with the machine tool manufacturer for diagnostic/repair purposes." Several machine tool builders are offering Internet-based links between their service departments and machine tools, but this is not a universal offering. And as for the "adaptive learning" aspect, while there are some pieces of machines that are offering adaptive control of one sort or another, there is a long way to go before there are machine tools with what could be considered rudimentary intelligence.

Ballenger goes on to say that he's interested in "Assembly lines that are truly flexible and are built with ease-of-maintenance in mind." Or said another way: He wants assembly lines that have low-maintenance requirements. One more thing: He's looking for warranties that go "beyond the usual 12 months."

EVEN BETTER SUPPLIERS.

As our question was one that would fall within the "blue sky" category, a group involved with Freudenberg-NOK's Gasket Operations in Manchester, New Hampshire, got together and held a brainstorming session. Participating were Jo Ann Rotast, Six Sigma Black Belt; Paul Hailey, Project Engineering Manager; Steve Craghead, Tooling Engineering Manager; Charlie Spurrell, Product Engineering Manager; and Scott Morrison, Operations Manager. Among the ideas they'd like to have realized are:

* Predictive capabilities that can ID manufacturing defects without any operator inspection, intervention, or review.

* Dynamic simulation of finite element analysis (FEA) throughout a wide temperature spectrum.

* Injection units and hydraulic units that don't leak.

Of course, not everything that is desired is equipment- or system-oriented. They'd like to have more suppliers who understand and use design for Six Sigma methodologies, as well as those who can integrate Six Sigma-level performance in processes and process control.

FASTER & LESS OBTRUSIVE.

A group of Delphi Corp. executives and manufacturing engineers in the U.S. were polled on their interests, and what they'd like to have include:

* The ability to braze heat exchangers within a 60 second cycle time.

* Sonic leak detection systems.

* Programmable heat exchanger assembly equipment that have a changeover time of less than five seconds, which would permit one-piece flow while meeting the customer's takt time.

Meanwhile, another group of Delphi folks, this an Asia Pacific team of manufacturing engineers, have some different wishes, these not so HVAC-oriented:

* Shrink wrap that cures without heat or high temperatures. This would provide a number of advantages, including shorter cycle times, an elimination of hot surfaces, and the ability to pack products right away, without the need for cool-down time.

* UV-type adhesive that cures without the need for UV light. This would mean that there is no need for eye protection, or expensive UV equipment.

* Nondestructive test capabilities that would allow testing of applications that currently require destructive tests (e.g., things that have been ultrasonically welded, crimped, or riveted).

NEW SOFTWARE METHODS.

Dennis Klein, manager of Project Management, North America, Siemens VDO Automotive, is seeking additional flexibility in the hardware used in parts manufacturing. He points out, "You want tooling to be more flexible in order to recapture the capital investment on multiple products and product life cycles."

Klein makes another important point: "Software manufacturing is cutting edge in automotive." Just think of the importance of software to everything from engine control to braking to telematics. One of the things that he's interested in is a new means for "making" software. "There is no physical form to it. There is no history to it. It's highly intractable, which has driven people away from applying methods to it." They are, however, trying some out at Siemens VDO: "We are beginning to apply traditional manufacturing methods, such as lean manufacturing, to the production of automotive software." He's looking beyond a room full of programmers each doing his or her own part in creating software.

"Software is the new frontier in manufacturing and has become so huge in automotive that methods must be applied to control and manage its mass production," Klein maintains.

LEAN & EREEN.

Benteler Automotive is not only looking for the ways and means to achieve a competitive advantage through manufacturing technology advances, but its people are also interested in finding the ways and means to reduce waste--not only because the company is committed to lean production methods (it has been awarded with a Shingo Prize for its lean operations in Grand Rapids. MI), but because of environmental awareness.

Rob Depierre, vice president of U.S. Operations, says, "Our developments are intended not only to create a tangible competitive advantage for Benteler, but also to create less waste in the environment by reducing material, plant emissions and energy required to manufacture. One example is in the area of underbody e-coat systems." He's looking for in-line systems that are smaller than ordinarily available. He explains, "Smaller installations will enable lean manufacturing while reducing the high capital associated with the larger-capacity systems. Additionally, environmental advantages may be recognized through the reduction in heating requirements and the use of smaller pretreatment and waste-treatment processes."

PRESSING ISSUE.

General Motors Metal Fabricating Div. (MFD) is the part of the vehicle manufacturer that is responsible for producing many of the large dies and stampings that are used to produce cars and trucks; it operates 16 facilities in North America. While one might anticipate that Dan Juliette, MFD's director of engineering, might be interested in something along the lines of a new means to cut dies or a more capable press or a laser processing system, he answers, "If we could have a magic wand, what I would really like to have is a math-based tool that would perfectly predict springback in stampings made from mild steel, aluminum, and various grades of high-strength steel. We have tools today, but they are not as precise and accurate as we would like them to be. And because of this, we still have to build manual proof tools to finish the design for the stamping dies." Juliette goes on to observe that because this software doesn't exist, "It takes extra time to develop a vehicle." They are exceedingly interested in go ing fast throughout the GM organization.

TWIN-PALLET HMC FADAL--BOOTH A-8218

The twin-pallet HMC 400, a new horizontal machining center, features 20' x 24" x 20" XYZ travels and is designed For a 24/7 duty cycle to maximize performance and throughput. Features a 40-pocket, dual-arm automatic tool changer [ATC], with a 1.2-second, tool-to-tool change time. The dual arm ATC uses a synchronous swing motion, picking up the new tool and old tool simultaneously to make the tool change in one continuous motion. Tools are loaded From the back of the machine.

The company claims the HMC 400 maintains a constant temperature and ensures positioning accuracy with its Cool Power refrigerated cooling system, which reduces thermal growth and position repeatability problems. The system is closed-loop, isolating the heat transfer agent from chips and other contaminants.

Other machining centers to be demonstrated include the new EMC entry level VMC and the new 50-Taper VMC 6535.

Fadal Machining Centers, 818-407-1400 www.fadal.com or enter 130 on the RSC.

MODULAR GRIP SYSTEM--ISCAR METALS, INC., BOOTH E-2317

The Modular Grip System is a new toolholder that combines all Grip systems in a single tool. This new toolholder can be used for all of the company's Grip products for external groove-turn, face groove-turn and parting applications.

The design is similar to the existing GHA holder, but has been modified to carry a wider selection of adapters apart From the GAO and PAD styles. The new toolholder can also carry screw-clamped adapters for Cut-Grip, Top-Grip, Heligrip and Heliface inserts.

Existing GAD, GAM and DGAD adapters can also be used with this toolholder. An advantage of this machine, according to the company, is that it is a single straight or perpendicular toolholder that can be used for many applications. Also, those who already use GAD, GAM or DGAD adapters will have more application options after switching to the new toolholder.

Iscar Metals, Inc., 817-258-3200

www.iscar.com or enter 131 on the RSC.

GAGE MEASUREMENT STATION--BROWN & SHARPE, BOOTH D-4303

The DCC gage measurement station from Brown & Sharpe is an entry level, high performance direct computer control coordinate measuring machine designed to improve throughput and accuracy in a variety of measurement and inspection operations.

The DCC GAGE can be used as a stand-alone, walk-up station for first piece inspection, layout inspection and tool set up, or as a flexible gage. Its large measurement envelope can handle workpiece sizes up to 18" x 20" x 16" (457 mm x 508 mm x 406 mm).

With a speed of 305 mm/second and acceleration of 290 mm/[second.sup.2], the DCC GAGE easily keeps pace with machine tools. In many applications, DCC GAGE can improve inspection efficiency up to 45%, significantly reducing machine tool idle time.

The DCC GAGE comes equipped with PC-DMIS PROsoftware, featuring on easy-to-use, shop-floor graphics interface that guides operators through part programming, setup and execution of the inspection routine.

Brown & Sharpe, 401-886-2000

www.brownandsharpe.com or enter 132 on the RSC,

VMC WITH Linear Drives-DMG America, BOOTH A-8501 On display will be the DMC 64/104 V linear series drives, a 12,000 rpm motor spindle, spiral chip conveyor and machine bed flush mechanism.

Also shown will bean inclined bed machining center, the DMP 60. This machining center uses an NC-swivel rotary table integrated pallet changer to achieve 5-sided/S-axis complete machining, Its linear drive axes realize 1.5 g acceleration and rapid traverse up to 3,936 ipm.

DMG America, Inc., 847-781-0277

www.gildemeisfer.com or enter 133 on the RSC.

COMPLETE METALCUTTING CELL on DISPLAY--TOYODA MACHINERY USA, CUTTING MACHINE DIV., BOOTH A-8018

FA450-III horizontal machining centers will be paired with a new, high speed, rail-guided vehicle [RGV] in a complete metalcutting cell on display.

The single-level stocker system will be shown with 12 pallets. It has a modular design and virtually unlimited capacity. The in-line configuration allows any number oF future machines, pallets or loading stations to be added without interrupting production. The machines are designed For high speed machining in a variety of applications. The standard model is equipped with a 30-hp, 14,000-rpm spindle. The machine achieves 1,969 ipm rapid traverse and cutting rates in all three axes. Its streamlined enclosure uses 40% less floor space, without reducing work envelope, accessibility or Features.

The flexible system will be shown with the company's newest cell controller software, which centralizes scheduling and production management for multiple machines at one shop-floor PC. According to the company, the Windows-based program increases machine and operator productivity up to 90% by selecting the most efficient production schedule and automating tasks.

Toyoda Machinery USA-Cutting Machine Div. 847-253-0340

www.toyodausa.com or enter 134 on the RSC.

COMPACT, EASY-TO-USE LASER MARKING SYSTEM-TRUMPF, BOOTH B-6500

TRUMPF will display the VectorMark compact, a valuable tool for various industrial and commercial marking tasks. TRUMPF's VectorMark compact offers a space-efficient, reliable and easy-to-use laser marking system.

The VectorMark compact occupies minimal floor space. The power supply and cooling system are fully integrated. Its small size, fully self-contained design, and single 115-volt electrical connection gives the user flexibility when positioning it on a busy shop floor.

The VectorMark compact is available as an OEM-component for integration in automated production lines and as a standalone workstation with a Class 1 safety enclosure and an integrated fume extractor. A motor-driven Z axis allows automatic adjustment of the focal distance to accommodate different workpieces; and a motor-driven vertical-lift front door simplifies exchanging the workpiece.

Trumpf, Inc., 860-255-6000

www.us.trumpf.com or enter 135 on the RSC.

ZEISS INTRODUCES NEW CENTERMAX PRODUCTION MEASURING CENTER-CARL ZEISS IMT CORP., BOOTH D-4501

To be shown is the new CenterMax Production Measuring Center. CenterMax was developed to meet the increasing need for adaptable measuring and inspection strategies in the production environment. Shorter production cycles, smaller batch sizes with maximum flexibility are the most important demands on the production departments and therefore on the measuring technology. The new, state-of-the-art bridge-type coordinate measuring machine can be used right next to machining centers. CenterMax offers increased resistance and accuracy, enhanced flexibility and optimized measuring volume.

Carl Zeiss IMT Corp., 800-752-5181

www.zeiss.com/imt or enter 135 on the RSC.

MORI SEIKI'S SOLUTION IS OUT OF THE BOX-MORI SEIKI, BOOTH A-8418

Mori Seiki's new vertical machining center, the NV5000, robustly handles your applications using its X, Y, and Z-axis travels of 31.5-in. x 20.1-in. x 20.1-in. Chip-to-chip time has been minimized by using dramatically faster performance than that found in conventional machining centers. The durable automatic tool changer exchanges tools with the 3D tool magazine in just 1.0 second. The 12,000rpm spindle drive uses DDS [Direct Drive Spindle) gearless technology to bring out its full power at all speeds and provides acceleration to full speed in 0.97 seconds. Rapid rates of 1654-ipm further reduce non-cutting time.

Mori Seiki, 972-929-8321

www.moriseiki.com or enter 137 on the RSC.

MULTIPLY YOUR SAFEGUARDING POSSIBILITIES-SICK, BOOTH D-4358

SICK's PLS Proximity Laser Scanner is a non-contact presence sensing proximity scanner for stationary or mobile applications; it uses a sweeping infrared laser beam and a three-zone configuration. The LSI Laser Scanning Interface doubles the capability and effectiveness of the PLS, according to the company. The LSI allows the user to have two independent warning field outputs per PLS, enabling simultaneous monitoring of the Safety Zone and Warning Zone. There are two models of The LSI, one for two PLS and one for four PLS. With the maximum of 4 PLS connected, eight programmable safety and warning zones can be achieved.

This can be especially effective on free-running transport systems or automatic guided vehicles in production plants. It is possible with the LSI to monitor the speed of the vehicle and adapt the monitoring areas depending on the speed and direction of travel. Stationary applications also benefit from this ability.

SICK, Inc., 952-941-6780

www.sickusa.com or enter 138 on the RSC.

UP TO SEVEN MACHINING CENTERS IN A SINGLE CELL-TURMATIC, BOOTH A-8127

TriFlex flexible manufacturing cells are ideal candidates for production of small- to medium-size lots, plus they provide the flexibility to machine a wide variety of components, materials and configurations, up to 300 mm. Cutting-edge CNC rotary transfer technology makes possible five-sided machining at each of four stations in a single clamping. Machining multiple work-pieces per fixture can minimize cycle times and slash total per-piece costs. Basic TriFlex design integrates up to seven CNC machining centers into a single, compact, flexible manufacturing cell, saving valuable floor space, while the flexible tooling capacity allows 56 separate tools. A separate load/unload station makes it possible to change the component during machining. Machining is carried out over three machining stations using either two--or up to seven--machining centers.

Turmatic Systems, Inc., 314-993-0600

www.turmatic.com or enter 139 on the RSC.

MILLING AND TURNING INSERTS-VALENITE, BOOTH E-2305

One of the featured products is the company's new advanced PVD-coated [physical vapor deposition] SpectraTurn and SpecraMill inserts for turning and milling. These wiper geometry inserts are PVD-coated with TiAIN [titanium aluminum nitride] or AITiN [aluminum titanium nitride] to provide edge integrity and wear properties.

For turning, TiAIN-coated inserts, according to the company, can run up to 100% faster than uncoated grades and up to 40% faster than PVD-TiN-coated grades. For milling applications, TiAIN-coated inserts can machine up to a 50% higher speed than uncoated grades and up to 20% higher feed rates, the company says. AITiN inserts are developed to machine titanium and titanium alloys. AITiN has a higher aluminum content than the TiAIN coating, which is said to result in a coating with higher hardness that increases hot hardness and the oxidational stability of the coating. As a result, this coating is said to be useful for machining titanium and titanium alloys because it acts as an insulator, translating the high heat to the chip and not to the insert.

In addition, the company will be exhibiting Modco-engineered tooling, including QDT [quick delivery tooling] capabilities; HSK; VM modular quick-change and shrinker tools.

Valenite, Inc., 248-589-7556

www.valenite.com or enter 140 on the RSC.

MYCENTER -3XI SPARKCHANGER WITH 180-DEG ROTATION 2-PALLET APC-KITAMURA, BOOTH A-8027

The Mycenter-3Xi Sparkchanger is ideal for machining highly toleranced components in higher quantities. The efficient 180 degree rotating 2-pallet system guarantees that your workpieces will be presented to the spindle both quickly and positioned with the utmost accuracy. Guarding between the work envelope and pallet station allow for precision machining while another pallet is being safely unloaded and reloaded by the operator. The Mycenter-3Xi features a state-of-the-art Kitamura-Fanuc 16iM control. Kitamura has packed this control with numerous high-performance features.

Kitamura Machinery of U.S.A., Inc. 847-520-7755

www.kitamura-machinery.com or enter 141 on the RSC.

RELATED ARTICLE: IMTS PREVIEW: AN ABBREVIATED LOOK

Here's a quick sampling of some of the items of interest that will be on display at the 2002 International Manufacturing Technology Show [IMTS] from September 4 to 11 at Chicago's McCormick Place. For a more exhaustive look, check out our sister publication Modern Machine Shop [www.mmsonline.com] or the Association for Manufacturing Technology's IMTS site at www.imtsnet.org.