This McKinsey & Company article Supply Chain 4.0 in consumer goods describes in its future state vision how the increased use of automation will result in a more efficient supply chain where "Robots handle the material (pallets or boxes as well as single pieces), completely automatically the warehouse process from receiving/unloading, to putting away, to picking, packing, and shipping".

Automation is a disruptive force not only in how work gets done, but in how the demand for talent needs to change, according to one of the key findings in this Boston Consulting Group article Twelve forces that will change how organizations work . The authors note that "Companies will require increasing numbers of programmers and other highly skilled digital talent, along with an enormous upgrade in the skills and capabilities of these workers...individuals and organizations will have no choice but to invest in massive, ongoing skill development programs."

1, 2, 3 – Quickly Picking the Box

When it comes to automation solutions, there are two wishes at the top of every company’s list: An increase in productivity and less strenuous work for the employees. Georg Fischer in Herzogenburg (Austria) has put both into practice – the versatile PLB robot guidance system from SICK facilitates a robot to overtake the heavy-duty work, and thanks to the speed of PLB, also does this in a highly efficient manner. Identifying, gripping, picking – this is how fast and reliable bin-picking is done.

Randomly oriented metallic parts in a box – locating them in a fast and reliable manner is the task set the PLB system from SICK.

Inventors, model builders and home improvers are familiar with the following: One is looking for a certain part or tool – either in a more or less chaotic arrangement on the workbench, on shelves or in cupboards, which somehow seem to be connected to a hidden dimension. Sometimes, things seem to disappear into thin air. “Desk jockeys” who have to search for and find important documents between other sheets of paper know what we are talking about. And when one does finally find what one was looking for, the following sentence might have been uttered at some time or other: “Keeping things tidy is for dummies. The genius, however, is able to master chaos.” In an automated facility for the handling of heavy exhaust manifolds at Georg Fischer, this genius is called PLB – the robot guidance system from SICK.

Identifying, gripping, picking

When it comes to depositing parts on the trolley, the PLB system guides the robot.

Georg Fischer (GF) is among the world’s leading suppliers of cast iron and cast light metal parts for the engine, the chassis as well as the body of commercial and passenger vehicles. This requires more than just dexterity – for the handling of exhaust manifolds, the company from Herzogenburg relies on the PLB robot guidance system from SICK.

The task at GF: The manifolds must be picked from a bin and placed on a trolley – a monotonous and taxing duty, as the parts would have to otherwise be moved manually. The challenge: The cast parts are randomly oriented in the boxes, which makes reliable identification and accurate localization a must for automated picking – which is not a problem for the precision work of the PLB system.

Localization of parts in bins

Developed for the exact determination of the position of components in bins and boxes, the PLB system is especially used for applications in which parts need to be localized and individually entered into the production processes. As is the case, for example, in the handling of both unfinished and completed cast parts or forgings. These are often transported between processing stops in collective bins. And in the course of the assembly processes, “picking the bin” is also sometimes indispensable – for example when parts and/or components are to be removed from material boxes or palettes.

Taught in an instant

The conditions in the casting house are best described as harsh – the molten metal is turned into exhaust manifolds.

The CAD-based “teach-in” of new parts in the PLB system allows for a simple configuration in the event of new applications, guarantees short calculation time and ensures a high throughput. The system comprises a 3D camera (ScanningRuler), part localization software as well as helpful tools for simple robot integration and communication with a higher-level control system. The specifically designed camera provides exact 3D images and is impervious to the influence of artificial lighting conditions. Tested and proven tools and functions for, the alignment of the PLB system with the robot coordinates system, the communication with the robot, as well as verification of the collision-free positioning of the robot gripper allow for a speedy integration of the system into production. All hardware and software components are delivered prepared for immediate utilization.

Optimal 3D image recognition for metal surfaces

The camera, which features an integrated laser light source, allows for millimeter-precise 3D point cloud measurements. The camera also provides 3D images for easy performance monitoring by the user.

The functionalities of conventional machine vision systems are often not sufficient for robot guidance. Such systems, for example, lack functions for the alignment of coordinates with the robot or for the identification of collisions during positioning of the gripper in the bin. Furthermore, new applications frequently require a significant amount of programming, which rapidly results in an increase of required time and application development.

The PLB system from SICK is the remedy. It offers all the tools required for robot integration and features 3D image recognition optimized for the identification of metal surfaces – which is perfect in order to increase the level of automation in parts handling, at GF in their application, in no time at all.

At the core: The ScanningRuler

The ScanningRuler from SICK provides precise and reliable 3D measurements of stationary objects – ideal for the utilization of robot-assisted bin-picking applications.

At the trade fair “Automatica” in Munich, the persons in charge at Georg Fischer were looking for possible solutions to their specific task at hand, they repeatedly encountered the ScanningRuler from SICK as a component utilized by different suppliers and integrators. The camera also forms the core of the PLB system. The ScanningRuler provides precise and reliable 3D measurements of stationary objects. This makes it the ideal camera for 3D image processing in robot-assisted bin-picking. The collected data can be used to localize parts or to compute the best gripping position for robots.

The camera, which features an integrated laser light source, allows for millimeter-precise 3D point cloud measurements across the entire range of the image, even under the influence of interfering light sources. Connection between the rugged Scannning Ruler and PC is done using industry proven Ethernet connectivity.

Metallic surfaces and contours

The PLB system ensures computation of the robot’s optimal gripping position.

Peter Friewald, Automation Specialist at GF: “We have found that the identification of complex metallic contours – such as those of exhaust manifolds – is a scenario that many suppliers of vision solutions have problems with. The 3D image recognition of the PLB system, which is optimized to identify metal surfaces and contours, on the other hand, convinced us right from the start. Format changes can also be carried out in a simple manner. At present, five different types of parts are being processed with the system.” In order to simplify the configuration, Peter Friewald has created an individually designed graphic user interface on the basis of the standard program, which optimally meets the requirements of GF.

More flexibility

Peter Friewald, Automation Specialist at Georg Fischer: “The 3D image recognition of the PLB system, which is optimized for the identification of metal surfaces and contours, convinced us […] right from the start.”

Peter Friewald is happy to have found the optimal solution for the handling of the manifolds: “The reliability during identification as well as the uncomplicated submission of data to the robot were in any case a pre-requirement. Due to the different types of parts, flexibility, i.e. a quick and simple “teach-in”, was a just as important topic. Following intensive fact-finding and product comparisons, we have implemented the PLB system – the right decision, as we have been able to significantly increase our throughput and now have more breathing space. The integration of further processing centers for additional manifold types is not a problem, either. No matter whether transport trolley or bin – the PLB system ensures the reliable handling of our parts in a flash.”

Original article post by SICK on SICKUSAblog

In this excellent McKinsey & Company article covering the Fourth Industrial Revolution, the authors highlight that "organizations too often overinvest in technology while underinvesting in the human capabilities needed to make it useful. The real lesson from technology leaders is that they apply it judiciously, as part of a broader transformation of the way they do business, starting with their people."

When Machines Can Monitor Themselves

Consistent quality, very few rejects, reliable part and batch tracking, added transparency: The use of vision sensors for quality control directly in the production process offers a number of benefits. Depending on the task at hand, you need to have the right vision solutions, which allow for quick and efficient integration into your machine.

The later an error is detected in the production process, the more costs it incurs and scrap material it causes. In light of this, it is therefore essential to detect errors as early as possible. At the same time, the evaluation of quality attributes enables users to identify any measures needed in production facilities or for production material. Vision sensors are ideal for dealing with these issues. Their spectrum stretches from 2D monitoring for simple production features and operating material attributes to high-end tests using 3D vision systems. Rejects and costs are cut as a result. Yet another benefit: The individual images from the vision sensors are stored and kept available for a later date – perfectly in keeping with the principles of Industry 4.0 and added transparency. Vision solutions used to be used primarily for monitoring production material at end customers. However, an increasing number of machine manufacturers and OEMs are joining the trend of incorporating the issue of quality control into their machines and plants – another step towards creating complete solutions for the end customers.

The benefit of inline Quality control is, that it detects errors at their source:

Forming Machine Tools, Punch Press

Vision sensors like the Inspector conduct ongoing checks of the punched contours or holes directly in the process. Irregularities or errors in the punching process are therefore detected immediately and with full reliability. An added bonus even for the flexible production of small batch sizes: The operator can access pre-defined test parameters when changing a batch or use functions to modify the parameters himself – so you don’t need to be a vision expert. The results of the thorough check are evaluated in the vision sensor itself and passed on accordingly.

Cutting Machine Tools, Powertrain

Are all of the holes and recesses in place and correct? To conduct a full quality check after processing a motor block, an Inspector vision sensor not only checks that all contours and holes are in place, it also makes sure they are the right shape. Any parts that have not been processed correctly can be rejected before further processing. The production process can then be stopped in good time, for example, if you need to replace any damaged tools. Furthermore, the sensor uses taught-in features to identify the individual parts. This information is sent to the control unit for the next machine in the line so that the production process can be modified if necessary.

Injection Molding Machines: Position Monitoring and Quality Control

The plastic and rubber industry requires a high level of efficiency and economy with a consistent level of quality. The use of vision solutions offers a number of benefits: For instance, a vision sensor can check whether an insert has been placed correctly into the injection molding machine’s mold. Having the component in the right position prevents damage to the tool and, as a result, reduces machine downtime, while at the same time improving the quality of the part in question. In the production of injection- molded plastic parts, the quality of the final product also depends on a number of factors, such as temperature fluctuations, fluctuating quality in the plastic granules, etc. Inline quality control using vision sensors can also offer advantages in this case: Errors such as over- or underfilling are detected reliably so that faulty parts can be safely separated and ejected.

Monitoring Welding Caps and Laser Nozzles

When welding or cutting metal panels, the quality of the welding caps on the welding gun or laser cutting device has to be monitored on an ongoing basis. Welding caps wear off as the processing time increases, requiring them to be replaced. An Inspector 2D vision sensor checks defined parameters, such as shape and diameter, and detects irregularities that cannot be tolerated. The operator can then replace the welding caps in good time so that product quality remains consistent.

Quality Control in the Processing of Sawn Timber

Powerful 3D vision solutions make a valuable contribution to the quality of the final product. For example, the Ranger E 3D vision sensor can generate an exact image of the surface of the board when processing sawn timber. As a result, potential errors and undesirable irregularities on the board, such as cracks, gaps, spots, rot, resin, or knots, can be clearly detected. This inline quality check using 3D vision solutions is equally well suited for the production of flat glass and plastics.

Original article from SICK posted on SICKUSABlog

This McKinsey article CPG manufacturers need a comprehensive strategy for digitization highlights findings from a recent McKinsey survey of senior CPG leaders that talent management has failed to keep pace with the needs of a digitally focused organization and that a lack of skilled resources  is a major obstacle to realizing benefits.

If your company has fewer than 100 employees and is in Robotics, Cybersecurity, Digital Health,or Internet of Things (IoT), check out the recently launched MassTech Intern Partnership (MTIP) program for Summer 2017.  It reimburses up to 50% of an eligible intern's gross salary for up to 2 interns.

May 18, 2017 Schedule of Speakers

10:45 AM - 1:00 PM

METALWORKING FLUIDS – THE WHOLE PERSPECTIVE

Building 1, Manufacturing Brilliance Theater, Booth #1266

10:45 AM - 1:00 PM

WHY MOST COMPANIES FAIL TO CREATE SUCCESSFUL LEAN TRANSFORMATION (AND WHAT TO DO ABOUT IT)

Building 3, Room 302

11:15 am - 11:50 am

ADDITIVE MANUFACTURING: ANOTHER TOOL IN THE MANUFACTURING CHAIN

Building 1, Manufacturing Brilliance Theater, Booth #1266

1:25 pm - 2:00 pm

DELIBERATE LEADERSHIP IN A DISTRACTED WORLD

Building 1, Manufacturing Brilliance Theater, Booth #1266

Click on any of the links above to learn more about what the topic is and who the presenter will be!

Sign up now using this link https://l.feathr.co/eastec-2017-gibson-engineering-co-inc-p

Video Review of Eastec 2015!

When walking around the show feel free to stop by Gibson Engineering's booth 3129! Reach out and contact us f you would like more information on attending the show!

Thanks you,

Brett Concannon

Gibson Engineering Co, Inc

Robots in the Electronics Industry:

Fast, Precise, Flexible – Thanks Intelligent Sensor Technology

In virtually every country, quality requirements are increasing, innovation cycles are getting shorter, and wage costs are rising. As a result, demand for robot-based automation solutions is growing within the electronics industry. Easier collaboration (e.g., thanks to compact and lightweight robots) is opening up additional applications for the market and offers huge potential for new customized automation solutions.

The new InspectorP65x programmable 2D camera from SICK can be used in TFT display test cycles and quality tests.

Until now, the possibilities for automation within electronics production have been limited. Conventional robots have often proven inflexible, been too expensive to buy, and have been too big and bulky. Now all that is changing with the advent of new and lighter robot arms. As well as being lightweight, compact, and flexible – and easy to program and operate – these robots are becoming suitable for more and more applications. Without any need for laborious installation work, they can take care of monotonous tasks and increase the efficiency of production processes.

And if the robot works side by side with workers instead of operating on its own or if it functions as mobile robot station, SICK offers perfectly aligned sensor solutions from a single source to help ensure safe collaboration and movement.

When What Counts is Maximum Repeatability and Precision

To enable the robots to see, sensors have to take them by the hand so to speak. Robot guidance that uses 2D or 3D image processing to locate objects plays a key role in optimizing industrial production processes.

If a robot is forced to work in an environment where the conditions do not remain constant, it cannot manage without a camera system. The robot has to be told how a component is positioned or whether its position has changed so that it can adapt to product variations. This enables it to assemble components that previously had to be put together by hand because they could not be processed by automatic placement machines (such as smartphone enclosures or electronic components for the automotive industry). And it can do this with maximum repeatability and precision. Without any need for laborious installation work, robots can take care of monotonous tasks and increase the efficiency of production processes. They can compensate for mechanical inaccuracies and can – within certain limits – cope with unknown situations while still delivering highly accurate measured values.

Not Just a Question of Visual Judgement and Mechanics

The robot detects the positions of predefined objects using the Inspector PIM60 2D camera, which can be mounted on the robot itself.

The Inspector PIM60 2D camera from SICK is already a proven component for robot guidance applications. The robot uses the camera (which can be stationary or mounted directly on the robot) to detect the positions of predefined objects and can decide for itself how to grip the part. This does away with the need for mechanical attachments such as object guides. In addition, the system relieves employees of non-value creating tasks such as resorting parts on a vibrating table. The system can also be used for measurements and quality inspections, e.g., monitoring of adhesive beads. Using a pattern, optical monitoring systems compare the position, gaps in, and quality of the adhesive used in the joining process and document any errors. The camera sensor allows complete contour inspection and workpiece monitoring immediately after the adhesive is applied. The components are adaptable, resulting in maximum flexibility. Thanks to the open platform, many robot systems are easy to reconfigure and adjust for new production tasks. If specific techniques and processes are required, they can be added with ease.

Original article posted by SICK on the SICKUSABlog

How Technology Liberates Human Capital is an excellent op-ed piece in the Wall Street Journal by Michael Milken and Igor Tulchinsky highlighting the need for new education and training opportunities for workers to be able to participate in a manufacturing environment with advanced technologies of artificial intelligence and smart robots. (note: you may need to log-in or subscribe to view the full article).