Mechatronics & Industrial Maintenance for Manufacturing

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1 Mechatronics & Industrial Maintenance for Manufacturing Tampa Bay Mechatronics Forum February 2014 Keith S. Campbell Director, Industrial Maintenance Training Center Principal Campbell Management Services, LLC

2 Topics Manufacturing is complicated A simplifying model for manufacturing Mechatronics in manufacturing Definition Impact on manufacturing Matching training & education programs to regional needs The credentials conundrum Best Practices & Success Factors 2

3 Chemicals Refining Smelting Manufacturing is complicated Air Products Exxon Alcoa Long Runs Months Change of material state Fluids / Pipes / Thermal Measurement Energy efficiency Food Beverage Printing Consumer Hershey Pepsi Donnelley P&G Differing Manufacturing Technologies Ford / Harley Boeing Caterpillar Automotive Aerospace Equipment Short cycles - minutes Change of geometry Metal removal / Parts Assy Logic Planning & logistics Manufacturing Continuum 3 Process Hybrid Discrete

4 Manufacturing Segments Discrete manufacturing Logistics driven: bringing components together Mechanical transformation Aircraft, automobiles, electronics, machinery Automation, PLC s, CNC s Process manufacturing Efficiency driven: long runs of things in pipes Chemical transformation Oil refining, casting, paper making Process control, DCS s, PID Similar to non-manufacturing segments mineral extraction and utilities Hybrid manufacturing Combination of process and discrete possibly with batch operations Physical transformation Often have large packaging operations Consumer goods, food, beverage, pharmaceuticals Sometimes use different automation strategies and different engineering and maintenance teams in different ends of the plant 4

5 5 US manufacturing segments

6 Technical Skills Vary by Segment There isn t a one-size-fits-all solution Skill Level Coordinated Cascade Multi-axis CNC Control Motion Control Control Proportional Valves Pneumatics Hydraulics Common core skills math, electricity, mechanics, motors Manufacturing Continuum Process Hybrid Discrete

7 Industrial Maintenance & Mechatronics is important (but different) for each segment Manufacturing jobs have leverage Largest economic and job multiplier effect of all industry sectors, each supporting 2 supply chain jobs and 2 consumer sector jobs Skilled manufacturing jobs have even more leverage, sometimes credited with supporting 7 to 11 other jobs Industrial Maintenance Jobs have the highest leverage In central PA, we lost over 300 production jobs for lack of 40 maintenance technicians A skilled technician can keep one line working over 3 shifts A skilled technician can have tremendous impact on OEE 7

8 Definition of Mechatronics The synergistic application of: Computer Science Mechatronics Mechanical Engineering Electrical Engineering 4 legged stool definition Controls Engineering to create useful products. 8

Mechatronics & Manufacturing A Paradigm Shift for Equipment

to 0 Belts - 15 to 0 Drive sprockets - 15 to 0 Spline shafts -

3 Line shafts - 6 to 0 Total - 118 to 23 (81% reduction) Case

electro-mechanical machine to a mechatronic machine.

9 Mechatronics & Manufacturing A Paradigm Shift for Equipment Design & Maintenance Moving part count reduction Pulleys - 45 to 0 Belts - 15 to 0 Drive sprockets - 15 to 0 Spline shafts - 2 to 0 Gearboxes - 16 to 10 Motors - 1 to 10 Bearings - 18 to 3 Line shafts - 6 to 0 Total to 23 (81% reduction) Case Study in Mechatronic Design Evolution from a PLC-controlled electro-mechanical machine to a mechatronic machine. Courtesy of R.A. Jones Packaging, General Mills, Inc., OMAC Packaging Workgroup 9

10 Mechatronics in Manufacturing A dramatic shift for industrial maintenance Enabling for existing industry (manufacturing, farm equipment) Foundational for emerging industry (photo-voltaics, wind) World-class manufacturers require integrated mechatronic machinery designs to be competitive You can t put multiple technicians on an airplane or have six prima donnas arguing over whose fault it is that the plant isn t producing Operations and maintenance requires new thinking More / different technical skills required of operators An (r)evolution is taking place from multiple crafts (electrician, mechanic, programmer, instrument technician, etc) to multi-skilled industrial maintenance technicians Electro-mechanical technician Advanced Manufacturing / Integrated Systems Technician AM/IST The capstone of this is the mechatronics technician 10

11 Mechatronics impacts all levels Engineering science trapped in our silos. Engineering technology first program at Purdue, emerging slowly Technicians community college degree and certificate programs, vo-tech programs, incumbent worker training Lots of jumping on the bandwagon as funding became available Many are electro-mechanical programs Finding appropriate breadth and depth of skills Programs need to be focused to careers Product vs plant focus Design, assembly, troubleshooting & maintenance Discrete, hybrid, process segments 11

12 Meeting Regional Needs Marketing 101 Know your customer Know your consumer Deliver value to each Where they want it When they want it How they want it Build solutions to satisfy the market need 12

13 Example - Confectionery Bars Very different customers with needs for different service levels, price points, products, packaging,. Walmart The Mart is different from Sam s Grocery store chain Convenience store chain Very different consumers with needs for different products, packaging, price points Teenage boys Hispanic European Moms Seasonal & holiday variations for all of the above 13

14 Applied to mechatronics Customers - employers Discrete / hybrid / process May break it down even finer Engineering science or engineering technology Engineering technology tends to be more about local needs Product design focus or plant operational focus How many jobs? - sporadic or continuous hiring Consumers students / workers 14 Conventional degree candidates High achievers and/or the forgotten middle half? Incumbent workers Unemployed / underemployed / ex-offender / veteran Aspirations operator / technician / designer Funding methods

15 15 Top Manufacturing Industries by Jobs Region = Hernando, Hillsborough, Pasco, & Pinellas Counties, Florida

16 16 Top Manufacturing Occupations

17 Regional industries and jobs mapped to model Where should resources be focused? Skill Level Not a top area Cascade Control Proportional Valves Soft drinks, printing Coordinated Multi-axis Motion Control Pneumatics CNC Control Hydraulics Common core skills math, electricity, mechanics, motors Packaging Machine operations Manufacturing Continuum Assembly, machining Electronics, machining, medical devices Maintenance Operations Process Hybrid Discrete These programs are expensive Lab equipment for common core skills ~ $750K For any pyramid ~ > $750K Plus facility, staff training, etc.

18 The Credentials Conundrum Credentials are common in healthcare, transportation, other areas When asked, most manufacturers will say they don t care about credentials Concerned about employee mobility Concerned about lack of quality too often lowest common denominator / one-size-fits-all solutions Today, programs funded with federal $ s are REQUIRED to provide an industry recognized credential $1/2 billion recently granted for manufacturing programs 18

19 19 The Credentials Conundrum Metalworking segment has most access to credentials Few choices in industrial maintenance and mechatronics NIMS for basic machine tool maintenance Siemens Mechatronics, using the German educational model PMMI, emerging using a US model Industrial Maintenance Training Center Advanced Manufacturing/Integrated Systems Technician US DOL Mechatronics Competency Model PMMI competencies and certification program This is a challenge for schools The easy alternatives Lowest common denominator certificates Default to existing certificates, letting 2/3 of manufacturers out Florida will have to address the credentials issue, while meeting the regional needs of customers and consumers

20 PMMI Certificate Architecture Level Skill A B M K I G C N L J H Hybrid Manufacturing Mechatronics Certificates Operative Skills MSSC NIMS D E F Manufacturing Continuum 20 Process Hybrid Discrete

21 Industrial Maintenance Training Center Credentials Yellow AM/IST 1 entry level electromechanical technician Blue AM/IST2 senior electromechanical technician Green AM/IST 3 - mechatronics technician 21

22 22 One Community College s Solution

23 IMTC Program Attributes Competency-based / not curriculum-based Engineering technology focus rather than science Adjust breadth and depth Extremely hands-on Real industrial equipment Builds from fundamentals opposite of German programs Align shafts, use a chain breaker, Ohm s law Heavy focus on troubleshooting teach it as a science, do it Components, machines, systems of machines Multi-disciplinary Mechanics, fluid power, electrical, controls, computers, robotics, motion, integrated manufacturing Integrated skill sets 23

24 24 Success factors to consider Ask the best of the best, listen, understand. Look over the horizon. Regional strategic advisory board for vision, local industrial advisory boards for tactics. Focus public resources on the top 1/3 of manufacturers. Recognize that these programs are expensive. Adults first it pays the overhead and insures quality Use the public education system for industrial training, forcing it to catch up. Provide a path to college credit for workforce training and already mastered skills. No repeating.

25 Success factors to consider 25 Sell credentials to minimize customization Provide training when and where needed without fixed start and end dates. Collaborate and articulate credit amongst schools. Facilitate student movement from school to work to school. Reject lowest common denominator solutions. Target needs specific to industry segments. Hands-on experience with real industrial equipment and documentation; labs, labs, labs. Teach and practice troubleshooting as a discipline.

26 Success factors to consider 26 Provide stackable industry credentials that provide early & intermediate achievement and exit points. Focus on infrastructure and delivery. There is more than enough curriculum. New credit hour / contact hour model may be required. Typical lab hours / credit. Utilize modular e-learning to the fullest. Plan and deliver across conventional departments. The earliest point of failure Create a model to align high school, community college, university and work.

27 Thank-you! Campbell Management Services LLC Bridging the gaps between: People & technology Technology & business Services include: Technology planning Organizational development Geek leadership Capital justification Curriculum review & development Board & advisory services Clients have included: Packagers Packaging machinery builders Technology providers R&D organizations Professional associations Educators Workforce agencies 27 Keith S. Campbell President & Principal Consultant Retired Director of Automation & Factory Integration, The Hershey Co. Board Member, JLS Automation & Formerly Vice-President Western Operations Contributing editor / blogger, Packaging World Magazine, OnTheEdgeBlog.com Former Director, Food & Pharmaceutical Industries Division, Instrument, Systems & Automation Society Founding Director and former Executive Director, OMAC Packaging Workgroup

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