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The classic manufacturing conundrum is how to make products quicker, cheaper, and better.

Until the middle of 2010, first-tier subcontract machinist, JJ Churchill, could produce turbine blades only if they had their fir-tree root-forms preground elsewhere, or if they were subsequently added by another subcontractor. No longer is this the case.

Why use a metrology device on or near a machine tool? It isn’t just useful for making sure a tool is present or monitoring tools for wear or breakage. On-machine measurement technologies can save time and money, by speeding up processes and eliminating extra personnel, and they are a critical step in the movement towards “lights-out” manufacturing.

Micro components continue to shrink in size, demanding ever-greater precision and improved handling of parts with sub-micron-sized features. New approaches in micro machining technology include higher-precision systems from traditional micro machining developers, as well as techniques using additive manufacturing processes and semiconductor wafer-scale technology on the smallest of micro parts.

The challenges to manufacturing as it evolves into the 21st century are now familiar, and impact how metrology must contribute. Manufacturers face uncertain production volumes with roller-coaster demand, shorter production runs and faster product development cycles. Automation, while alluring as a way to reduce cost, needs to adjust.

When you walk into the Redeye On Demand facility in Eden Prairie, MN, you enter into one version of the factory of the future. There you will see a bank of 100 high-end Fortus fused-deposition modeling (FDM) machines from Stratasys that provide the capacity to build real, functional parts with production-grade thermoplastics directly from CAD data.

To remain competitive in the fiercely contested North American automotive industry, the New United Motor Manufacturing Inc. (NUMMI, Fremont, CA) assembly plant, a joint venture between Toyota Motor Corp. (Aichi Prefecture, Japan) and General Motors Corp. (Detroit), has rededicated its efforts in lean manufacturing during the past few years by applying key tenets of the Toyota Production System (TPS). 

IIoT expert Steve Jones who will speak Oct. 29 at “The Best of SMX” (smxevent.com), describes in detail the Industrial Internet of Things (IIoT), as well as AI/machine learning and other promising technology for manufacturing’s future. Like with many things in life, it is important to set goals first, the Steelcase executive says. Not sure where to begin with IIoT? Never fear: Jones has the answer.

Craig Zoberis and Davin Erickson detail how Fusion OEM discovered and implemented collaborative robots, or cobots. The company is now investing in future expert machinists by using cobots—and making headway in closing the manufacturing industry skills gap. They explain the phases of training for cobots, as well as how cobots “talk” with other machines—and how machines perform “handshakes” (and are therefore envied by humans who today are struggling with social distancing).

Diego Tamburini, principal industry lead for manufacturing in the cloud + AI division of Microsoft, reviews the impact of the COVID-19 crisis in manufacturing. He shares his thoughts about how the industry should respond—and lists the attributes of manufacturers best positioned to survive the crisis. Finally, he outlines new opportunities for developers of smart manufacturing software solutions under the “new normal.”