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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


Three Strategies for Effective Innovation

Manufacturers that want to improve their product development process must be market readers, need seekers or technology drivers.

by Austin Weber


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


Glossary of Lean Manufacturing Terms

Lean manufacturing uses many different words and terms. Click here to learn the difference between "kaizen" and "jidoka."

by Austin Weber


Digital Controls Are Similar for Different Types of Welding

Digital controls are basically similar for different types of welding equipment.

by Austin Weber


Ultrasonic Welders Assemble Lithium-ion Batteries

Lithium-ion batteries require extra assembly steps than other types of rechargeable batteries. Some manufacturers use ultrasonic welding to assemble their batteries.

by Austin Weber


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


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


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


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


Leak Testing Supplier Solves Trio of Automotive Challenges


Over the past year, the engineers at Vacuum Instrument Corp. have designed numerous leak testing systems for assemblers of all sorts of products. Here are three from the automotive industry.


by John Sprovieri


Glossary of Lighting Terms

Here are some common terms used to describe lighting systems and technology.

by Austin Weber


What to Look for in a Lighting System

Several different types of lighting systems are available for assembly workstations. Here's some advice on what to look for.

by Austin Weber


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


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


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


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


2007 Assembly Plant of the Year: Giving Back to the Community

The men and women who work at the Schneider Electric/Square D Lexington plant donate time and money to a wide variety of local charities.

by Austin Weber


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


2007 Assembly Plant of the Year: Environmental Initiatives

The Schneider Electric/Square D Lexington plant is committed to protecting the environment. It has initiated numerous green programs over the last few years.

by Austin Weber


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


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.




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."




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.


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


The Inside Story: Numerous Sources Inspire Interior Designers

Automotive design engineers look to many sources of inspiration when creating interiors. Years before a new model reaches the market, designers must select fabrics and materials for the interior trim.


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


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


2006 Plant of the Year: Lear Sees Big Demand for Comfort and Convenience

Comfort and convenience features used to be found almost exclusively in expensive luxury vehicles, but not anymore.


2006 Plant of the Year: When it Comes to Being Green, Lear’s in Gear

Lear Corp. (Southfield, MI) promotes green manufacturing in its plants and works closely with automakers and suppliers to reduce the environmental impact of its products.


2006 Plant of the Year: New Lear Technology Transforms Car Interiors

More and more automakers are focusing on interior craftsmanship as they seek appearance goals that set their products apart from the competition.


2006 Plant of the Year: Lear’s 7-Pronged Product Development Strategy

Faster time to market is a critical business objective for all automakers today. The goal is to get new vehicles to consumers quicker than ever.


Lean Manufacturing: Glossary of Lean Manufacturing Terms


Going Wireless: Numerous Concerns


The Build-to-Order Challenge: Build-to-Forecast vs. Build-to-Order


Some Change is Good: Equipment Integration Challenges


Some Change is Good: Glossary of Packaging Terms


See and Avoid Saves Profits: The High Cost of Warranties


RFID on the Line: Glossary of RFID Terms


RFID on the Line: Spending Will Accelerate This Year


Assembly Plant of the Year: High-Tech Tools Improve Assembly


Assembly Plant of the Year: A Lean, Green Printing Machine


Assembly Plant of the Year: Supply Chain Efficiency Is Key to Success


Assembly Plant of the Year: Xerox ‘Toys’ With Innovation


The Shipping Dock: Glossary of Packaging Terms


Safety First: Sensors Drive Active Safety Systems


Safety First: Auto Safety Technologies Enter the Fast Lane


Inspection System Improves Diesel Assembly: Flexible Plant Assembles V-6 Diesels


Packaging for Point of Sale: Glossary of Packaging Terms


Packaging for Point of Sale: Integration Challenges Face Manufacturing Engineers


Molding for Medical Device Assembly: Plastic Trends, Issues and Challenges


Molding for Medical Device Assembly: Glossary of Injection Molding Terms


Managing the Reality of Offshore Assembly: Where U.S. Manufacturing Jobs Went*


Leveraging the Supply Chain: How Manufacturers Can Improve Profits


Managing the Reality of Offshore Assembly: Five Questions to Answer Before Going Offshore


Leveraging the Supply Chain: How DaimlerChrysler Does It


Robot Dos and Don’ts: Glossary of Robotics Terms


Lean Workstations: Glossary of Ergonomics Terms


Lean Workstations: Glossary of Lean Manufacturing Terms


Rivets, Steam and Sweat: How It’s Done Today


Tracking Parts: How to Select a Reader




Tracking Parts: Readability Is Also Important




Medical Device Frontiers: Researchers Develop a New Device for Self-Monitoring


Medical Device Frontiers: Demand for Cardiovascular Products to Remain High


Medical Device Frontiers: Microelectronic Medical Devices Are Hot


Off-Road Equipment: A Look Into the Future


Assembly Plant of the Year: Kenworth Gets an ‘A’ for Compliance


Assembly Plant of the Year: Coloring Book Shows How Kenworth Trucks Are Built


Assembly Plant of the Year: When the Hauling Gets Rough, the Tough Turn to Kenworth


Off-road Equipment: Business Outlook Is Rosy for the New Year


Automakers Do More With Less: How Diesel Engines Work


Nanotech Frontiers: Nanotech Holds Great Promise, But Also Poses Big Challenges


Nanotech Frontiers: Glossary of Nanotechnology Terms


Automakers Do More with Less: New Technology Boosts GM Production


Nanotech Frontiers: Next 10 Years Will See Huge Growth for Nanotech


Nanotech Frontiers: American Public Bullish on Nanotech


Glossary of Lean Manufacturing Terms


Automakers Do More With Less: Mechatronics Will Affect How Future Cars Are Built


The World’s Top-Quality Auto Assembly Plants


Automakers Do More With Less: Lightweight Materials Continue Making Inroads


Automakers Do More With Less: Foreign Auto Industry Continues Investing in U.S. Plants


Error-Proofing in Dispensing

Are there ways to prevent mistakes during dispensing?