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The Pros and Cons of Robotic Ultrasonic Welding
Robotic ultrasonic welding can be used to join metal or plastic parts. The technology is ideal for some applications, such as welding battery packs, but may not be difficult to justify for other projects.
by Austin Weber
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Adhesives and Tubing
Although plastic medical tubing can be joined to itself, it’s often attached to a device, bag or connection. As medical device manufacturers look for alternatives to traditional solvent welding, demand for adhesives is increasing.
by Austin Weber
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Plastic Tubing Bonding Tips
Medical tubing is made from several types of plastic, including polyvinyl chloride (PVC), polyethylene, thermoplastic elastomers, nylon and silicone. Traditionally, PVC is most widely used, because it bonds easily with other plastics. However, non-PVC tubing is often more difficult to bond.
by Austin Weber
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Automated Tube Assembly Is Easier Said Than Done
Traditionally, plastic medical tubing is manually attached to valves, connectors, catheters, and other devices. But, medical device manufacturers are eager to automate the assembly process. It’s being driven by several trends, such as labor shortages, labor costs and increased levels of quality control.
by Austin Weber
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Ball Chairs—Fad or Fabulous?
Many grammar schools around the United States are using ball chairs in the classroom. The devices force students to frequently change positions to maintain balance. That leads to increased alertness and concentration. Ball chairs can be modified with wheels, arm rests and back supports for assembly line applications. However, the devices have pros and cons.
by Austin Weber
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Adjustable Seating Contributes to Productivity
Adjustability is a key factor when choosing assembly line seating, especially in today’s flexible, lean work environment. Engineers should look for chairs that feature adjustable heights and back tilts. How the chair and the operator fit together is crucial.
by Austin Weber
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Sitting vs. Standing Makes a Big Difference
The main difference between seated and standing workstations are in reaches and clearances. Seated work requires more leg clearances, and cannot accommodate long reaches. Work surface heights can vary for standing work.
by Austin Weber
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Look Inside—Foam Is Important
Foam is an important element to look for when selecting assembly line seating. However, the type of foam used in the construction of a chair is something that’s often overlooked. Foam is produced with varying characteristics and quality.
by Austin Weber
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Make vs. Buy Worksheet
Engineers must ask numerous questions when determining whether to make or buy automated assembly systems. Here are 24 important things to consider.
by John Wirtz
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Make or Buy Pitfalls to Avoid
One of the keys to success in any business endeavor is to avoid the pitfalls experienced by other companies that have traveled down the same road before you. Here are 12 important things to consider when pondering the make or buy decision.
by John Wirtz
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Northrop Grumman Invests in Robotics
Northrop Grumman Corp. is investing more than $100 million in an integrated assembly line for the F-35 Lightning II jet fighter program. The automated line will enable the company to produce one center fuselage per day.
by Austin Weber
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How a Casket Is Assembled
A steel casket is more than just a large metal box. The 2009 Assembly Plant of the Year uses many different manual and automated assembly processes to create a dignified product with an elegant look.
by Austin Weber
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The History of Caskets
The casket industry traces its roots back to ancient Egypt and Mesopotamia, where wood, cloth and paper were used to make sarcophagus-style burial boxes. In the United States, casket manufacturing developed in the late 19th century. Today, it is a $1.2 billion industry and Batesville Casket Co. is the leading manufacturer.
by Austin Weber
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Guiding Principles
All employees at the 2009 Assembly Plant of the Year adhere to the “Manchester Guiding Principles,” a philosophy that strives to cut costs, improve quality, boost productivity and improve time to market. Ten basic principles form the backbone of all manufacturing activity at Batesville Manchester.
by Austin Weber
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Safety First!
Safety is something that’s taken very seriously at the 2009 Assembly Plant of the Year. In fact, Batesville Manchester’s large water tower sports an outline of the state of Tennessee with the slogan “Volunteer for Safety.” Communication and education also play a key role in the process.
by Austin Weber
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Lean and Green
The 2009 Assembly Plant of the Year strives to be a lean and green facility. Batesville Manchester has an active environmental program that focuses on waste disposal and efficient use of energy.
by Austin Weber
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New Surgical Tools Will Drive Ophthalmic Device Industry
Demand for ophthalmic devices that enable minimally invasive surgery will grow dramatically during the next four years. In particular, the implantable device sector will surpass the market share of contact lenses, glasses and ophthalmic drugs, predicts a new study by Frost & Sullivan Inc.
by Austin Weber
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Air May Be Key Ingredient of Future Batteries
Reducing the size and weight of batteries with the necessary charge capacity has been a long-running challenge for developers of electric cars. A new type of air-fuelled battery developed in Scotland could solve the problem. It provides up to 10 times the energy storage of designs currently available.
by Austin Weber
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From Foot Power to Battery Power?
Engineers at the University of Leeds are developing a way to capture the kinetic energy produced when soldiers march and use it to power their equipment. The new energy harvesting system is designed to convert foot-power into battery power.
by Austin Weber
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Printable Batteries Solve Weight Problem
Traditionally, automotive batteries have been bulky and heavy. But, some day in the future, batteries may be printed rather than assembled. A new battery developed by engineers at the Fraunhofer Research Institution for Electronic Nano Systems is less than 1 millimeter thick. It weighs less than 1 gram and can be economically mass-produced by using conventional printing processes.
by Austin Weber
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Viruses Grow Lithium-Ion Batteries
In the future, lithium-ion batteries may be produced in a test tube. Engineers at Massachusetts Institute of Technology (MIT) have manipulated viruses to build both the positively and negatively charged ends of a lithium-ion battery. The new virus-produced batteries have the same energy capacity and power performance as state-of-the-art rechargeable devices being considered for automotive applications.
by Austin Weber
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It's a Great Time to Be a Battery Engineer
Advanced battery technology is one of the hottest topics in the auto industry these days. Because of all that activity, this is a great time to be a battery engineer in Detroit. The industry is hungry for chemical engineers, electrical engineers and manufacturing engineers who can help address challenges such as finding new ways to make batteries lighter, stronger and more powerful. It also helps if you have some good ideas on how batteries can be mass-produced quicker, safer and more cost-effectively.
by Austin Weber
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Inside GM's New Battery Plant
A plain-looking warehouse near Detroit is being transformed into a state-of-the-art lithium-ion battery assembly plant. General Motors Co. (GM) is investing $43 million in the facility to mass-produce battery packs for the Chevrolet Volt and other extended-range electric vehicles. When the 160,000-square-foot facility opens next year, it will be the first lithium-ion battery manufacturing plant in the U.S. operated by a major automaker.
by Austin Weber
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Human Eye Inspires New Type of Camera Lens
The human eye is a delicate organism that’s difficult to copy. But, a team of engineers at Northwestern University and the University of Illinois hope to mimic the eye in a new type of camera lens they are developing. They have created an array of silicon detectors and electronics that can be conformed to a curved surface.
by Austin Weber
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Electronic Contact Lenses Create Virtual Displays
Engineers at the University of Washington have combined a flexible, biologically safe contact lens with an imprinted electronic circuit. The device contains an electronic circuit, as well as red light-emitting diodes for a display.
by Austin Weber
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The 'Holy Grail' of Ophthalmic Devices
Believe it or not, the bionic eye is more fact than fiction. A device called Argus II is currently being developed by engineers at five U.S. Department of Energy laboratories and four universities. The high-density microelectronic-tissue hybrid device aims to restore sight to people blinded by diseases such as age-related macular degeneration and retinitis pigmentosa.
by Austin Weber
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Layoffs and Paycuts Will Subside During Second Half of 2009
According to the 2009 ASSEMBLY State of the Profession survey, budget cutbacks, time constraints and global competition will continue to create big challenges for manufacturers during the next five months. But, things should be less stressful than they were during the first half of 2009. A recent study conducted by Mercer LLC also indicates that deep workforce, pay and benefit cuts will moderate during the next five months.
by Austin Weber
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Lay-On Instead of Lay-Off?
Are layoffs really the best answer to a sluggish economy? “No,” according to the CEO of a small company who believes it's not about who’s “essential” and who’s “expendable.”
by Austin Weber
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Older Workers Delay Retirement
Many workers are being hit by large losses to their retirement funds. At the same time, a significant number of older workers are planning to delay their retirement. In fact, 60 percent of respondents to ASSEMBLY Magazine’s 2009 State of the Profession survey have changed their retirement plans because of the economy.
by Austin Weber
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Stainless Steel Challenges
Most foodservice equipment manufacturers rely heavily on stainless steel. The shiny material is widely used to make commercial coolers, dishwashers, fryers, ovens, refrigerators and other products because of universal demand for corrosion resistance, durability and hygiene. However, it presents unique assembly challenges to manufacturing engineers.
by Austin Weber
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Energy Efficiency Is Top Green Concern
Energy efficiency is a hot topic these days in many different industries, including foodservice equipment. But, despite numerous advantages, several barriers prevent companies from investing in energy-efficient products, such as limited funding, uncertainty about future energy prices, government incentives, and energy and climate legislation.
by Austin Weber
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Gasket Design Rules
Engineers have several factors to consider when designing for a formed-in-place gasket. However, with a few calculations, engineers can save a few cents on every gasket. In a high-volume operation, such savings can really add up!
by Axel VanBriesen
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Robots Play a Key Role in F-35 Assembly
To increase throughput and reduce production costs on the new F-35 Lightning II , engineers at Northrop Grumman Aerospace Systems are using commercial six-axis robots for drilling and fastening applications.
by Austin Weber
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Using Robots Is 'Just Plane Crazy'
Every year, BEST Robotics Inc. organizes a competition for more than 10,000 students at more than 700 middle and high schools. The nonprofit organization encourages kids to learn about robotics and pursue careers in engineering. During the 2008 competition, students were challenged to develop the best way to assemble an aircraft using robots.
by Austin Weber
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Robots vs. Fixed Automation
Traditionally, commercial and military aircraft are assembled with large gantry machines. However, those device are expensive. And, they typically have limited throughput and require a large amount of space on the plant floor. Unlike gantry systems and other large, heavy pieces of fixed automation, robots are more flexible, less expensive and can be quickly deployed.
by Austin Weber
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Aerospace Automation Consortium Touts Robotics
The Aerospace Automation Consortium, an independent group of aircraft manufacturers and production equipment suppliers, recently issued a white paper that outlines key industry challenges.
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Accuracy Is No. 1 Challenge
The aerospace industry has talked about using robots for many years. However, until recently, most efforts were hindered by accuracy issues.
by Austin Weber
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Plastic Joining Challenges Under the Hood
Automakers and suppliers are using plastics, such as nylon, polyphenylene sulfide and polypropylene, in engine compartments to reduce vehicle weight and improve fuel efficiency. Many different grades of material are available to choose from. Ultimately, the application and its requirements will dictate what materials are suited for use under the hood.
by Austin Weber
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Ford Gets Flexible in Louisville
Ford Motor Co. has spent $200 million to retool its Kentucky Truck Plant in Louisville. In addition to F-Series pickup trucks, the flexible factory will assemble Ford Expedition and Lincoln Navigator sport utility vehicles, which were previously assembled at a plant outside Detroit.
by Austin Weber
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A New Take on Flexibility
Whenever engineers think about flexibility, aluminum-framed modular conveyors and workstations often come to mind. Most people don’t think of an entire automotive assembly line. But, Volkswagen AG recently opened a new line in South Africa that highlights the benefit of flexible assembly equipment.
by Austin Weber
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Plastic Improves Oil Sumps and Oil Pans
Automakers and Tier One suppliers will be assembling more oil sumps and oil pans from plastic in the near future. They are eager to replace steel and aluminum components with nylon.
by Austin Weber
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Plastic Helps Auto Engineers Tackle Weight Challenge
Contrary to popular belief, automobiles have not become lighter during the last 15 years. In fact, they have become 30 percent heavier. But, plastics under the hood help shed excess weight without compromising the comfort and safety features that are mainly responsible for the upward weight spiral.
by Austin Weber
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Automotive Aluminum Use Reaches Record High
While plastic continues to turn up in more and more engine compartments, aluminum use is also increasing. In fact, a recent study claims that the use of automotive aluminum in North America is at an all-time high.
by Austin Weber
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Three Key Metal vs. Plastic Questions
The ongoing quest for lightweight vehicles is forcing automotive engineers to look for new ways to replace metal powertrain components with plastic. Here are three important questions to ask.
by Austin Weber
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Bioplastic Is Used to Make Radiators
A Tier One supplier is using plant-derived nylon resin to produce automotive radiator end tanks. It is the first time that a bioplastic has been used in mechanical components exposed to the hot, chemically aggressive underhood environment.
by Austin Weber
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Dual-Clutch Transmission Relies on Plastic
Dual-clutch transmissions are popular because they help improve fuel efficiency. A Tier One supplier uses nylon to make integrated control units for its transmissions.
by Austin Weber
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Plastic Plays Big Role in Tiny Nano
Last week, the much-anticipated Tata Nano “people’s car” went on sale in India. The $2,000 microcar, which has been hailed as the 21st century’s Model T, promises to open up motoring to an entirely new group of consumers. The car features a plastic air-intake manifold.
by Austin Weber
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Survival Tips
When business conditions are slow, manufacturing engineers should take the opportunity to fine-tune their operations. Here are six tips to consider.
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The Role of Robotics in Flexible Manufacturing
When most engineers think about “flexibility,” they imagine robots. The devices can perform a wide variety of repeatable tasks. But, their flexibility is limited by some programming and parts feeding challenges.
by Austin Weber
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In-Wheel Motors May Revolutionize the Auto Industry
Future generations of green vehicles will depend on in-wheel motors. The technology involves a combination to wheels, tires, motors, brakes, steering, suspension and cooling systems. It eliminates the need for traditional components such as engines, transmissions, differentials and transmission shafts, which can result in a 10 percent to 25 percent weight reduction and a 20 percent to 30 percent fuel savings.
by Austin Weber
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X-Prize Inspires Green Innovators
If you have a good idea for building an extremely fuel-efficient vehicle, the X Prize Foundation wants to hear from you. The goal of the prize is to inspire a new generation of production-capable vehicles that can exceed the equivalent of 100 miles per gallon. Teams that successfully compete in a series of stage races held in different parts of the United States will be eligible to share in a $10 million award.
by Austin Weber
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Extreme Flexibility
A truly flexible assembly plant could produce cars, aircraft engines, refrigerators, cell phones and bagpipes on the same line. However, that type of scenario probably will never happen, because there are limits to flexibility. In fact, the most flexible type of factory may be a disposable factory.
by Austin Weber
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How to Measure Flexibility
The word “flexible” is defined many different ways by different manufacturers. That inconsistency can make it difficult to measure and monitor the effectiveness of flexible assembly lines.
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Flexible Challenges
No matter where or how it’s applied, the ultimate goal of flexible manufacturing is always the same: Greater responsiveness to customer demands, in addition to reduced changeover time and quicker time to market. But, exactly how much equipment reconfiguring and reuse can be done, and how much it costs, is subject to debate. Manufacturing engineers must address several myths and misperceptions that surround flexibility.
by Austin Weber
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How to Keep Operators Productive in a Downturn
Many assembly lines are currently running much slower than this time last year. As a result, there’s a lot more idle time on plant floors these days. Keeping employees busy is crucial to keep workplace morale and productivity high.
by Austin Weber
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Offense vs. Defense
To survive today’s chaotic and volatile world, manufacturers should get in touch with their inner football coach and adopt a defensive game plan.
by Austin Weber
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Traditional Technology May Zap Electric Car Market
At the recent North American International Auto Show in Detroit, Chrysler, Ford, General Motors, Toyota and other automakers unveiled a wide variety of all-electric vehicles that they hope to have on the market in just a few years. However, the auto industry may remain dominated by cars powered by traditional internal-combustion engines (ICEs) for several more decades.
by Austin Weber
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Age Is an Important Ergo Factor
Ergonomic guidelines have always been important. However, they are even more critical now because of the changing demographics of the work force. For instance, today’s assembly line workers are often older and more diverse than in the past.
by Austin Weber
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Why Ergonomic Guidelines Aren't Followed
Numerous ergonomic guidelines exist. Unfortunately, they are not always followed correctly on the plant floor. Some manufacturers are indifferent to guidelines because of a lack of understanding, cost-cutting pressure or lean manufacturing initiatives.
by Austin Weber
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Fuel Cells Face Fuzzy Future
Automakers have been pouring billions of dollars into developing fuel cell technology. But, it will be at least another decade before they begin mass production.
by Austin Weber
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New Players Reach for the Sky
Numerous start-up companies are attempting to carve out a niche in the green car market. Unfortunately, they face huge obstacles, such as the global recession, low gas prices and the credit crunch, that will limit their ability to succeed.
by Austin Weber
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Battery Manufacturing – Build It in the USA
Lithium-ion batteries are today’s hot technology in the auto industry, yet most of the products are made overseas. But, the domestic battery manufacturing infrastructure will be getting a big boost thanks to several new assembly plants.
by Austin Weber
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Some Knees Are Gender Benders
Orthopedic device manufacturers have developed “gender knees,” which accommodate numerous shape differences between the average male and female knee, such as narrower shape and thinner density.
by Austin Weber
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Knees Need Special Assembly
Knees are one of the most complex types of orthopedic implant to manufacture. Artificial knees must accommodate a range of motion up to 120 degrees, allowing them to naturally bend and rotate.
by Austin Weber
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Titanium Coating Improves Orthopedic Implants
Medical engineers at the Georgia Institute of Technology have coated a titanium implant with a new biologically inspired material that enhances tissue healing, improves bone growth around the implant, and strengthens the attachment and integration of the implant to the bone.
by Austin Weber
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Bone-Growing Nanomaterial Could Improve Artificial Joints
For artificial implants to be successful, bone must meld to the metal that artificial hips, knees and shoulders are made of. A team of engineers at Brown University have discovered that bone cells are more apt to adhere to a rough carbon nanotube surface than other surfaces.
by Austin Weber
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Demand for Orthopedic Implants Will Skyrocket
The number of hip and knee replacement surgeries performed in the United States has skyrocketed over the last decade. According to the American Academy of Orthopaedic Surgeons (AAOS), there will be a 101 percent increase in hip replacements and a 550 percent increase in knee replacements between now and 2030.
by Austin Weber
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Microbatteries May Provide Tomorrow's Power
The energy for the next generation of miniature electronic devices could come from tiny microbatteries about half the size of a human cell and built with viruses. Engineers at the Massachusetts Institute of Technology (MIT, Cambridge, MA) have developed a battery that could one day power a range of miniature devices, by stamping them onto a variety of surfaces.
by Austin Weber
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Thin-Film Batteries Hold Promise
After years of development in the research lab, thin-film batteries may finally be ready for widespread commercialization. The devices are appealing to many manufacturers because they feature customizable shapes, flexible form factors and ultra-low weight that enables new functionality to be added to a broad range of products.
by Austin Weber
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Ergonomics: Honda Innovates
Assemblers at the Honda Motor Co. (Tokyo) plant in Sayama, Japan, are using a new contraption to eliminate the risk of repetitive-stress-related injuries. The walking assist device helps support bodyweight to reduce the load on an individual's legs while walking, going up and down stairs, or working in a semicrouching position.
by Austin Weber
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Ergonomics: Ford Simulates
Engineers at Ford Motor Co. (Dearborn, MI) use digital tools and virtual manufacturing technology to simulate assembly tasks. That helps them predict and eliminate repetitive-stress and other on-the-job injuries.
by Austin Weber
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Ergonomic Milestones
Occupational ergonomics is not a new field. In fact, people have been studying the topic for more than 100 years. This brief timeline tracks some significant milestones.
by Austin Weber
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Glossary of Ergonomic Terms
The field of ergonomics is full of various terms, such as "carpal tunnel syndrome" and "cumulative trauma disorder." Here's a short guide to everything from "accommodation" to "work reach envelope."
by Austin Weber
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Batteries Power a Robust Market
Batteries are one of today’s hottest products, with billions of dollars being poured into various R&D efforts around the world. While automotive applications heat up, consumer electronics will continue to drive the market in the near future.
by Austin Weber
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World-Class Supply Chain
By applying lean manufacturing principles and supply chain efficiency, the 2008 Assembly Plant of the Year has been able to minimize product complexity. Design for supply chain techniques have been used at IBM Poughkeepsie to create more common parts, resulting in cycle time improvements and cost reduction.
by Austin Weber
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Green Sigma Initiative
The 2008 Assembly Plant of the Year is a leader in green manufacturing. In fact, the IBM High-End Server Plant in Poughkeepsie, NY, is a pilot site for IBM’s new Green Sigma consulting initiative, which was launched in August.
by Austin Weber
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A Helping Hand in the Community
The men and women who work at the 2008 Assembly Plant of the Year in Poughkeepsie, NY, are proud of their local community. For instance, more than 2,500 IBMers in the mid-Hudson Valley region have volunteered more than 260,000 hours to help out schools and not-for-profits through the company’s On Demand Community efforts.
by Austin Weber
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Innovative THINKing
For many years, International Business Machines Corp. (IBM) has been synonymous with the word “innovation.” In fact, the streets within IBM’s 500-acre campus in Poughkeepsie, NY, home of the 2008 Assembly Plant of the Year, feature names such as Assembly Ave. and Innovation Way.
by Austin Weber
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The Smart People Behind the Smart Products
The 67-year-old IBM High-End Server Plant in Poughkeepsie, NY, manufactures extremely complex machines. In fact, many of the devices built in the plant rank among the world’s fastest and most powerful computers. But, those smart machines would never operate if it weren’t for an even smarter bunch of humans. Click here to view a slideshow featuring some of the men and women who work on the line at the 2008 Assembly Plant of the Year.
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Next-Generation AGV Technology
Traditionally, automated guided vehicles (AGVs) have lacked flexibility, which has limited their ability to quickly and easily change paths or routes. But, new technology will allow the devices to make smarter judgments and more intelligent decisions on the plant floor.
by Austin Weber
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Benefits of Robotic 'Safe Motion'
By implementing robots equipped with safe motion technology, manufacturers will be able to improve safety, reduce the size of workcells and increase operating efficiency.
by Austin Weber
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The Lean Side of AGVs
Conveyors and forklifts have long been synonymous with assembly lines. But, in a lean world, those types of traditional material handling tools are often frowned upon. Some manufacturing engineers believe that automated guided vehicle (AGV) technology provides a better way to reduce waste and streamline production flow.
by Austin Weber
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AGVs vs. Conveyors
Some experts question if conveyors still make sense in today’s lean, flexible world. They believe automated guided vehicles (AGVs) can be a better alternative for material handling, depending on the specific application.
by Austin Weber
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Robot Safety Challenges and Opportunities
"Safe Motion" is still a relatively new concept in the robotics industry. Many challenges still need to be addressed before the technology is widely accepted.
by Austin Weber
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New Report Covers Robot Safety Standards
The Robotic Industries Association (RIA, Ann Arbor, MI) has introduced a new technical report that provides guidelines for implementing ANSI/RIA/ISO 10218-1-2007. The RIA R15.206 technical report explains how to implement and use next-generation robots that comply with the new international robot safety standard.
by Austin Weber
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How 'Safe Motion' Works With Robots
"Safe Motion” is a concept that allows humans and machines to work in close proximity to each other. However, not all robot manufacturers interpret and define safe motion the same way. ASSEMBLY recently asked a group of experts to share their thoughts on the subject.
by Austin Weber
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The Model T's Chicago Connection
When most people think of Henry Ford, the Ford Motor Co., or iconic cars such as the Model T, they automatically think of Detroit. But, believe it or not, Chicago (the hometown of ASSEMBLY magazine) actually played a key role in Ford’s fortunes and contributed to the company’s mass-production success story.
by Austin Weber
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Ten Ways the Model T Changed the World
The Model T is the car that’s credited with "putting the world on wheels.” Here’s a brief look at 10 ways the iconic vehicle influenced business and social conditions.
by Austin Weber
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How the Model T Was Assembled
There were 45 operations involved in producing a Model T chassis on the first moving assembly line, which debuted at Ford’s Highland Park, MI, plant in early 1914.
by Austin Weber
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The 5-Day Car Will Feature Lightweight Materials
Researchers in Europe believe the 5-day car will revolutionize automotive production. They have developed a lightweight modular car that features plastic body panels and new assembly methods.
by Austin Weber
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The Ultimate Lightweight Driving Machine?
Engineers at BMW Group (Munich, Germany) recently unveiled a shape-shifting concept car that takes the use of lightweight materials to a whole new level. Instead of using traditional metal, aluminum or plastic composites, the skin of the vehicle is made from a stretchy fabric that forms a wide variety of convex and concave surfaces.
by Austin Weber
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Steel Still Rules
While automakers are evaluating the use of lightweight materials, such as aluminum, composites and magnesium, they are also trying to make better use of traditional materials to lower vehicle weight. As a result, the use of sheet steel in automobiles may not decline rapidly, but be replaced using thinner grades of high-strength, low-allow steels.
by Austin Weber
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Magnesium Use Will Increase in Auto Industry
Because magnesium is one-third lighter than aluminum, it is very appealing to automotive engineers. More and more automakers use using magnesium sheets and castings in front-end engine compartment applications, replacing what is currently sheet steel. However, because of the lack of elasticity in magnesium, at times traditional thread-forming screws are not functional.
by Austin Weber
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Plastic Is a 'Heavy' Weight Champion
Plastic is the most common lightweight material used in automobiles today. However, automakers continue to find new uses for the material, especially in under-the-hood applications.
by Austin Weber
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New Process Reduces Cost of Titanium Auto Parts
Titanium is a strong, lightweight material that has always been too expensive for most automotive applications. But, that could soon change, thanks to a new process being developed by engineers at Oak Ridge National Laboratory.
by Austin Weber
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Lotus Races to Tackle the Lightweight Challenge
During the 1960s and 1970s, Team Lotus (Hethel, England) was synonymous with cutting-edge racecars, innovative engineering ideas and world-champion drivers. Today, the company if developing lightweight sports cars by focusing on sustainable materials such as hemp.
by Austin Weber
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State of the Profession: How Bad Is It?
The last time the U.S. economy suffered a recession was in 2001. While economic conditions today are similar, the overall outlook remains much healthier.
by Austin Weber
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Innovation Is Hot—Read All About It
Five recently published books explain how manufacturers can harness the power of innovation to compete successfully in today's flat world.
by Austin Weber
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Man-Machine Allocation
People are good at some things, and machines are better at others. It's important to distinguish between them when considering an automation project.
by Austin Weber
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Nanotechnology Transforms Lithium-ion Batteries
Researchers at Stanford University have developed a way to use silicon nanowires to improve the rechargeable battery technology used in cordless tools and other devices. The new technology produces 10 times the amount of electricity of existing lithium-ion batteries.
by Austin Weber
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Charging Technology Gets Smarter, Faster
Cordless tool manufacturers and their battery suppliers are focusing part of their R&D efforts on recharging technology. As a result, today's battery chargers are faster and smarter than ever.
by Austin Weber
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Medical Plastic Trends
Medical device manufacturers continue to consume more plastic than ever. ASSEMBLY recently asked two experts at a leading material supplier to comment on current market conditions.
by Austin Weber
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New Medical Plastic Is Inspired by Seashells
By mimicking the brick-and-mortar molecular structure found in seashells, researchers have created a new type of composite plastic that’s as strong as steel, but lighter and transparent. It could be used in microelectromechanical devices, microfluidics and biomedical sensors.
by Austin Weber
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How to Choose Task Lighting
Task lighting is supplemental lighting that is provided to assist in performing a localized task. Here are some tips on how to choose task lighting for assembly workstations.
by Austin Weber
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How Welding Has Changed Over 50 Years
This year marks the 50th anniversary of ASSEMBLY magazine. Since the publication debuted in the late 1950s, we have provided in-depth coverage of key trends, issues and challenges affecting the wide world of welding. Here's a look at how welding technology has changed over the last 5 decades.
by Austin Weber
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2007 Assembly Plant of the Year: The People Behind the Plant
More than 500 individuals work at the Schneider Electric/Square D plant in Lexington, KY. They assemble 2 million load centers and safety switches annually. More than 50 percent of the employees have been at the plant for 20 years or more. Click here to view a slideshow featuring some of the men and women who work on the line at the 2007 Assembly Plant of the Year.
by Austin Weber
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2007 Assembly Plant of the Year: Operators Play a Key Role
In addition to state-of-the-art assembly equipment, people also contribute to the success of the Schneider Electric/Square D Lexington plant. More than 50 percent of the workforce has been employed at the facility for 20 years or more.
by Austin Weber
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2007 Assembly Plant of the Year: A Vision of the Future
The Schneider Electric/Square D Lexington plant has been assembling residential load centers and safety switches since Dwight D. Eisenhower was president of the United States. But, a wide variety of production tools used today, such as vision systems, did not exist when the plant opened 50 years ago.
by Austin Weber
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Timeline: 50 Years of Economic Change and Manufacturing Progress
To celebrate ASSEMBLY magazine's golden anniversary, here's a year-by-year look at how things have changed, evolved and stayed the same over the last 50 years. The timeline focuses on engineering achievements, business trends and manufacturing milestones.
by Austin Weber
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Wire Makes the World Go Round: A Company Ahead of Its Time
For many years, Western Electric Co. (New York) was one of the largest wire processors in the world. The company boasted that it manufactured “43,000 varieties of telephone apparatus.” It invested heavily in state-of-the-art automated equipment to assemble complex wire harnesses used in telephone switching systems and other advanced telecommunications gear. Western Electric engineers also developed numerous time-saving innovations in-house, which ASSEMBLY frequently reported on.
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The Inside Story: Consumers Speak Out on Interiors
Researchers at Kelley Blue Book Co. (Irvine, CA) recently polled active car buyers on “overall cabin comfort.” They ranked the interior styling of vehicle brands based on headroom and legroom, as well as interior design throughout the cabin including “intelligent layout, quality materials, convenient compartments and superior ergonomics.”
Toyota Motor Corp. (Nagoya, Japan) topped the rankings in four of the seven vehicle categories: Minivan, non-luxury SUV, non-luxury sedan, and luxury sedan. General Motors Corp. (Detroit) took top honors in two categories: Trucks and luxury SUVs. Foreign automakers swept the top three spots in the convertibles and sports car, luxury sedan, and non-luxury sedan categories.
"Though some car reviewers have been critical of Toyota interiors, it is obvious they are a big hit with the public at large," says Jack Nerad, executive editorial director and executive market analyst at Kelley Blue Book. "On the truck side, General Motors turned in a dominant showing in the face of strong challenges from Toyota and Nissan, each of whom would like to capture a larger share of the truck market."
Specifically, here’s how automakers scored in each of the 7 categories:
*Convertibles/Sports Cars—Mercedes-Benz; Porsche; Lexus.
*Trucks—GMC; Chevrolet; Cadillac.
*Minivans—Toyota; Honda; Dodge.
*Luxury SUVs—Cadillac; Lexus; BMW.
*Non-Luxury SUVs—Toyota; Chevrolet; Ford.
*Luxury Sedan—Lexus; Mercedes-Benz; Infiniti.
*Non-Luxury Sedan—Toyota; Volkswagen; Honda.
"While the average consumer has not had a chance to sit inside each vehicle among every brand, perceptions play a large role in determining a new vehicle shopper's consideration set," notes Rick Wainschel vice president, marketing and market research at Kelley Blue Book. "Understanding consumer perceptions and shifts in those perceptions through tracking and trending . . . allows manufacturers to better understand how to market and attract potential buyers based on their perceptions prior to purchase."
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The Inside Story: LEDs Shed New Light on Interiors
Mood lighting and ambience lighting are one of today’s hottest trends in automotive interiors. According to the Lighting Research Center at Rensselaer Polytechnic Institute (Troy, NY), new light-emitting diode (LED) technology has led to a revolution in automotive lighting. It offers styling flexibility, energy efficiency, unlimited color options and high reliability.
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The Inside Story: Fasteners Hold Auto Interiors Together
Seats, instrument panels, floor consoles, trim and other automotive interior components are attached with a wide variety of fasteners. ASSEMBLY magazine recently asked Bob Gordon, central regional manager at PennEngineering (Danboro, PA), a leading supplier of fasteners, to share his thoughts and observations on the subject.
by Austin Weber
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The Inside Story: Modular Customization Is Future Focus
Traditionally, consumers have limited choices available when it comes to specifying interiors. For instance, most vehicles are equipped with either leather or cloth fabric seats. Instrument panels, floor consoles, headliners, door panels and trim typically come in beige, black, gray or white.
by Austin Weber
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Medical Robots Are Hotter Than Ever
More and more blood glucose monitors, inhalers, IV bags, orthopedic implants, pacemakers, stents, syringes and other products are produced with robots. Adept Technology Inc. (Livermore, CA) is a leading supplier of assembly robots for medical device applications. ASSEMBLY magazine recently asked Craig Tomita, director of the company’s medical products business, to share his thoughts on the challenges and opportunities currently affecting the market.
by Austin Weber
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Error-Proofing at the Workstation
Error-proof assembly is greatly assisted by error-proofing the setup process.
Ray Gottsleben, Sales and Marketing Manager, Arlink Workstation Systems
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Another Type of Removable Adhesive
The U.S. Air Force had a problem. It wanted an adhesive for temporarily attaching small test packages to the exterior of a jet without mechanical fasteners.
by John Sprovieri
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Outsourcing's Alphabet Soup
As outsourcing continues to evolve, it’s becoming more complicated. Indeed, depending on what acronym you use, outsourcing can mean different things to different people.
by Austin Weber
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How to Assemble a Model T
There were 45 operations required to build a Model T chassis on the first moving assembly line installed at Ford’s Highland Park, MI, factory.
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Automakers 'Flex' Manufacturing Muscle
American automakers have launched an aggressive campaign to transform their aging assembly plants into state-of-the-art agile facilities that can produce multiple vehicle platforms on the same line.
by Austin Weber
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Machine Safeguarding Resources
All automated equipment consists of three fundamental components: a point of operation, a power transmission device and operating controls. However, safeguarding needs vary widely due to different physical characteristics and operator involvement.
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Lean to the Rescue
Ross Controls (Troy, MI) is an international supplier of pneumatic and hydraulic controls, such as industrial valves. The 81-year-old independent company has an extensive product line that consists of more than 5,000 items.
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Mass Customization Demands New Thinking
Anne Stevens, vice president of North American vehicle operations at Ford Motor Co. (Dearborn, MI), referred to mass customization during her recent keynote speech at the 2002 Assembly Technology Expo in Rosemont, IL. According to Stevens, "customization" means making products in small lots or batches with volumes as little as one.
by Austin Weber
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Recreating History the Wright Way
Five separate groups of amateur aviators are vying to walk in the footsteps of aerospace pioneers Orville and Wilbur Wright. The goal of each organization is to build a reproduction of the Wright Flyer, the first aircraft to achieve the age-old dream of controlled and powered flight.
by Austin Weber
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AOI: Off-Line Inspection
Automated optical inspection does not have to be performed in-line. In some cases, off-line inspection may be more cost-effective. We asked Todd LaMarche, sales manager with Scienscope International Corp.'s Capital Div., for his thoughts on off-line AOI technology.
by John Sprovieri
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Metal vs. Plastic Ultrasonic Welding
Karl Graff, Ph.D., is a leading expert in the field of high power ultrasonics, including transducers, applications and systems.
by Austin Weber
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Ask Before You Buy
Before investing in equipment to tighten threaded fasteners, engineers should consider these questions.
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Reaction to OSHA's New Ergo Plan
The U.S. Occupational Safety and Health Administration (OSHA, Washington, DC) has abandoned its ambitious plan to enact an ergonomics "rule."
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Retooling a Legend
The first car to roll off the Lansing Grand River assembly line is the Cadillac CTS.
by Austin Weber
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Laser Welding Techniques
The laser energy necessary for welding can be presented to parts in the form of either a spot or a line. Spot or contour welding refers to the use of a circular spot of laser energy to traverse a preprogrammed contour path and create a weld.
by Austin Weber
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How Laser Compares
Laser welding compares favorably to traditional plastic joining techniques.
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Ultrasonic Selection Tips
Ultrasonic welders are available in several different frequencies, such as 15, 20 and 40 kilohertz, and a variety of power supplies, such as 1,000, 1,500, 2,000, 3,000 and 4,000 watts. It’s important to select the optimal frequency and power for your application.
by Austin Weber
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The French and Italian Connection
Today's power tool batteries owe their basic design and operating characteristics to a pair of 18th century Italian engineers and a trio of 19th century French scientists.
by Austin Weber
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Battery Trends
Without rechargeable batteries, cordless tools would be useless. As battery technology evolves, power tool manufacturers are continually searching for ways to make screwdrivers and other fastening tools more powerful, more lightweight and more durable.
by Austin Weber
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Personal Protective Equipment
After engineering and work-method considerations have been addressed, personal protective equipment is the final step toward reducing the potential risk of ergonomic injury on the assembly line.
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The Early Days of Ergonomics
Repetitive motion injuries have been plaguing assemblers for many years. In September 1970 (three months before OSHA was established!), ASSEMBLY Magazine first reported on a new term called "ergonomics."
by Austin Weber
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Simulation Tools
More and more manufacturers are using human modeling tools to simulate assembly tasks and evaluate ergonomic risks. The technology offers many advantages to manufacturing engineers.
by Austin Weber
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Intelligent Assist Devices
Ergonomic material handling equipment with computer-controlled servo drives can enhance an operator's lifting capability.
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Automating Wire Harness Design
Improving the design process for wire harnesses and cable assemblies can dramatically affect overall time-to-market, cost and quality of an electromechanical product.
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Cutting the Cord
No longer the province of the home workbench, cordless power tools are increasingly found on assembly lines.
by Adam Cort
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Ergonomics Q&A
Alan Hedge, Ph.D., is a leading expert on ergonomics and repetitive motion injuries.
by Austin Weber
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Automation Gets Smart and Agile
For manufacturers of medical, automotive, electrical, computer and telecommunications products, the next century will bring many of the same challenges as the previous century. Assemblies will get smaller.
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Anti-Fatigue Mats
Standing requires about 20 percent more energy than sitting, so assemblers who stand all day typically experience greater fatigue. Over long periods of time, standing can result in poor blood circulation in the feet and legs.
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Seeing the Light
Ergonomic assembly requires adequate visibility and illumination of the work area. Products that support this include lights, magnifiers and vision systems.
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Corning: An Automation Success Story
Once known primarily for rugged kitchenware, such as casserole dishes, Corning Inc. (Corning, NY) is now the world's leading producer of optical fiber, which it pioneered more than 30 years ago.
by Austin Weber
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Automated Tools Debut at OFC
A record number of exhibitors and attendees participated in the recent Optical Fiber Conference (OFC) in Anaheim, CA.
by Austin Weber
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What's Behind a Number?
It's fitting that the Boeing 717 is assembled with innovative production techniques, such as a continuously moving assembly line, because the airplane broke a long-standing tradition at the 85-year-old company.
by Austin Weber
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A Historical Perspective
Building airplanes with moving assembly lines is not a brand new concept. In fact, the process was successfully used during World War II to mass-produce military aircraft.
by Austin Weber
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Rated 'R' for Rotten?
Several leading manufacturers are experimenting with employee evaluation rating systems to determine pay raises and promotions. However, the job new review practice is extremely controversial.
by Austin Weber
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State of the Profession
Layoffs have become a fact of life in the manufacturing industry. Being prepared is the best defense against the threat of downsizing, which often occurs with little or no advance warning.
by Austin Weber
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Selecting Technology and Vendors
The process and the method are decided. Now it’s time to select the vendor for the project and choose the specific equipment and tools to execute the assembly operations.
by Austin Weber
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How to Evaluate Suppliers
Supplier evaluation is not an easy process. Many different formulas and techniques can be used. One effective method assigns suppliers to four basic categories based upon their level of performance in key areas, such as delivery, quality and responsiveness.
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Riveting Lore
Imagine that you're a contestant on the popular TV show, "Who Wants to Be a Millionnaire?"
by Austin Weber
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A Discrete Alternative
Traditionally, fiber optic devices have been assembled using various discrete components. Some observers believe integrated optical components, photonic chips and wafer scale manufacturing provide an answer to the assembly woes that have been plaguing the industry.
by Austin Weber
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Optical Components Fuel Fiber
Fiber optic communication requires more than just hair-thin strands of glass. A wide variety of optoelectronic components and photonic devices are necessary to generate, modulate, guide, amplify, switch and detect light.
by Austin Weber
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Corning: An Automation Success Story
Once known primarily for rugged kitchenware, such as casserole dishes, Corning Inc. (Corning, NY) is now the world's leading producer of optical fiber, which it pioneered more than 30 years ago. The $4.7 billion company spun off its famous cookware business in 1998 to focus on the booming fiber optics industry.
by Austin Weber
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