Assembly

ASSEMBLY
August 2009 www.assemblymag.com
Auto Supplier
Rides Winds
of Change
pg 14
Ophthalmic Assembly 22
Marking Dots, Stripes 30
Selective Soldering 34
ATExpo Preview 37
See us at ATExpo, Booth 507
Be the first to experience
the future of precision fluid dispensing.
ATExpo, Booth 705

August 2009 Vol. 52, No. 9
22
ASSEMBLY 66
COVER STORY 30
䡵
14 Automotive Supplier Rides Winds of Change
When a Nevada startup went looking for a
manufacturer to assemble a new type of wind turbine,
automotive supplier MasTech Manufacturing leapt at
the opportunity.—John Sprovieri
34
FEATURES DEPARTMENTS
䡵
22 Better One or Better Two? Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Time to back health care reform.—John Sprovieri
Ophthalmic device manufacturers keep an eye on new
technology.—Austin Weber Automation Profiles . . . . . . . . . . . . . . . . . . 8
System handles fragile components.—John Sprovieri
䡵
30 When All You Need Is a Dot Quality in Assembly . . . . . . . . . . . . . . . . . . 9
Software helps assemblers manage quality tasks.
Marking parts with colored inks or stains is a fast, —John Sprovieri
easy way to differentiate between similar-looking
We Fed It . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
components, indicate pass-fail status or confirm that a System feeds, assembles springs.—John Sprovieri
specific process has been performed.—John Keating
and Claude Bergeron New & Noteworthy . . . . . . . . . . . . . . . . . . 12
All-purpose gloves made from bamboo.
䡵
34 Riding the Mini Wave Assembly Lines . . . . . . . . . . . . . . . . . . . . . 16
Group launches wind energy data base.
Automated selective soldering technology saves EMS
facilities time and money.—Reed Gaither Assembly in Action . . . . . . . . . . . . . . . . . . 18
Single-cable camera maximizes efficiency.
䡵
37 Don’t Miss the Big Show Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Find the tools your company needs to succeed at Classified . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ATExpo 2009.—Adam Cort
NEXT MONTH
Automating Battery Assembly
Robot Guidance
Assembling With Lockbolts
Cover photo courtesy Mariah Power Assemblers Get a Lift
2 ASSEMBLY / August 2009 www.assemblymag.com

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ASSEMBLYtv and the interactive AssemblyBlog blog page. Ophthalmic Devices
Engineers are developing an artificial retina that includes 60
implanted electrodes to help patients with impaired vision.
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Editorial ASSEMBLY ®
1050 IL Route 83, Suite 200

Bensenville, IL 60106-1096
Phone 248-362-3700
Fax 630-227-0204
Time for Health Care Reform

TOM ESPOSITO
R
ecently, while cutting some fruit for breakfast, I Publisher
nearly sliced off the tip of my left index finger. After espositot@bnpmedia.com
much bleeding, abundant foul language, and a trip to BILL DEYOE
the emergency room, I’m happy to report the finger was Associate Publisher
deyoew@bnpmedia.com
saved.
Including a tetanus shot and skin glue, the bill for my JOHN SPROVIERI
Editor
mishap totaled an astounding $982. I shudder to think of sprovierij@bnpmedia.com
the bill had I been in a serious accident. Thankfully, I have AUSTIN WEBER
health insurance, but how long will that continue when Senior Editor
treatment for a simple cut costs nearly $1,000? webera@bnpmedia.com
Almost all U.S. manufacturers offer health benefits to ADAM CORT
their employees, but the rising cost of those benefits is impairing their ability Senior Editor
corta@bnpmedia.com
to hire workers, battle overseas competitors, develop new products, and invest
DONALD E. HEGLAND
in assembly technology. Employer-sponsored health insurance premiums have Editorial Director Emeritus
nearly doubled since 2000, a rate three times faster than wages. In 2008, the
MIKE ROBINSON
average premium for a family plan purchased through an employer was $12,680, Art Director
which is nearly the annual earnings of a full-time minimum wage job. According robinsonm@bnpmedia.com
to a 2008 survey conducted by the National Association of Manufacturers, 55 AMANDA PODINA
percent of small and midsized manufacturers reported that their health care costs Marketing Coordinator
podinaa@bnpmedia.com
increased by more than 10 percent during the past year.
The 2008 election seems finally to have goaded Congress to action. In July, LISA WEBB
Production Manager
the House and Senate released draft reform bills. The bills are too big to be webbl@bnpmedia.com
elaborated here, but here are a few key provisions. CAROLYN PERUCCA
People who get insurance through their employer would retain that coverage. Buyers Guide Project Leader
A new Health Insurance Exchange would be created so small employers and peruccac@bnpmedia.com
uninsured individuals could comparison shop among private and public insurers. CINDY WILLIAMS
Over time, the exchange would be opened up to all employers as another Corporate Reprint &
Trade Show Coordinator
choice for covering their employees. Premium subsidies would be provided to williamsc@bnpmedia.com
individuals and families with low and moderate incomes.
The measure is expected to cost $1 trillion over 10 years, a sobering number to
be sure. It will be paid for with a mix of tax hikes and spending cuts on programs
CORPORATE DIRECTORS
like Medicare. The House plan would apply an income tax surcharge on the
wealthiest Americans. Another possibility is to limit the tax exemption on the Publishing Timothy A. Fausch
most expensive health benefits plans from employers. Publishing John R. Schrei
Just as there can be no one solution to our increasing energy demands, health Audience Development Christine A. Baloga
care reform must take a multipronged approach to the myriad factors that drive Custom Media Steve M. Beyer
up costs. That means legislators on both sides of the aisle must swallow some Corporate Strategy Rita M. Foumia
bitter medicine. Sorry, Democrats, tort reform must be part of the health care bill. Information Technology Scott Kesler
Production Vincent M. Miconi
Too bad, Republicans, but a public option should be included in the insurance
Finance Lisa L. Paulus
exchange. Creative Michael T. Powell
Whatever bill emerges from Congress—and we must demand a legitimate Marketing Michele Weston-Rowe
proposal this year—manufacturers should get behind it. The worst we can do Directories Nikki Smith
is nothing. Human Resources Marlene J. Witthoft
Conferences & Events Scott Wolters
Clear Seas Research John Thomas
BNP Media Helps People

Succeed in Business with
Superior Information
Automation
Profiles
System Handles Fragile

Components
The glass ampoule is only 0.004 inch thick and very fragile.
of the glass. At station four, the filters are pressed into the tubes to
complete the assembly and retain the ampoule.
The fifth position was intentionally left free of tooling to fa-
cilitate access to the machine for cleaning and maintenance—an
often-overlooked part of sound machine design.
The sixth position inspects and records the assembled height of
the product. This is done with linear variable displacement trans-
ducers.
At station seven, good assemblies are off-loaded to the conveyor,
where the solvent is applied and cured. The solvent is dispensed
with a resolution of ±0.1 microliter. Bad assemblies are indexed to
station eight, where they are deposited in a bin.
What are the dimensions of the assembly? The machine han-
dles two different product sizes. One is 52 millimeters long; the
other is 72 millimeters long. Both are 8 millimeters in diameter.
What equipment feeds the parts? Vibratory bowls with bulk
hoppers feed the tubes and filters. The ampoules are fed manually.
We also had to develop innovative ways to deal with the static elec-
tricity generated when feeding thin plastic parts.
When designing this system to assemble an adhesive applicator, engineers What inspections are included? All parts of the assembly
knew that glass and adhesive can and will get everywhere that they do not are inspected for presence, orientation and assembled height.
expect it. Inspections are performed with photoelectric sensors, capacitive
proximity sensors and linear encoder-based contact probes.
H
andling glass can be challenging for any automation project. Additional sensors monitor the level and displacement of solvent,
Actuators and grippers have no appreciation for the delicacy as well as the correct position of every actuator on the machine
of an object. Glass parts in the wrong place at the wrong during operation.
time are no match for hardened steel. What is the production rate? 4,200 parts per hour. Only two
Allied Automation has designed several systems that process people operate the entire system.
thin glass containers safely and efficiently at high speeds. So when Can the system accommodate variants? The system han-
a medical manufacturer approached Allied to build a system to as- dles two different product sizes both with and without vent
semble an adhesive applicator, the company knew how to get the holes. Changeover is fully automatic. The product to be as-
job done. sembled is selected through the touch-screen, and all machine
Besides the adhesive itself, the applicator consists of a plastic adjustments are made automatically.
swab tube, a glass ampoule and a plastic filter tip. A solvent bonds What was the most challenging aspect of building the sys-
the filter to the tube. The ampoule is only 0.004 inch thick and tem? The system must handle an ampoule every second without
very fragile. In this profile, Allied’s president, Jeff Graham, and breaking any, and it must be easily accessible for cleanup when
engineering manager, Nathan Marshall, describe how the machine ampoules do break. It was critical to the success of the project that
works. we understood that glass and adhesive can and will get everywhere
For more information, visit www.alliedautomation.com or call that you do not expect it.
919-362-4440. We used chemical- and corrosion-resistant materials
throughout the machine. The system is enclosed with tem-
Describe the system. The machine has two components: an pered safety glass, so the windows stay clear even after
eight-station rotary dial and a recirculating puck conveyor. The cleaning with aggressive chemicals. All pneumatic actuators
dial is equipped with removable nests that hold four parts each. are equipped with corrosion-resistant rods. The system also
Each puck carries eight parts, and the conveyor accommodates 800 had to comply with FDA requirements and clean-room speci-
parts. fications. A
The first station places four tubes in a nest and inspects for them
presence and height. The second station lifts the tubes, supports Editor’s note: Whether you’re a systems integrator or the in-
them from the inside, and punches vent holes, depending on the house automation team of an OEM, if you’ve designed a system
product. (A product variant does not require vent holes.) that you’re particularly proud of, tell us about it. Send an e-mail
The third station gently places the ampoules into each tube. to John Sprovieri, editor of ASSEMBLY, at sprovierij@bnpmedia.
Tooling at this station confirms the presence, length and integrity com, or call 630-694-4012.

Q UALITY in ASSEMBLY
Software Helps Assemblers

Manage Quality Tasks
I
n these days of far-flung supply chains and the Food and Drug Administration.
When updated multiple assembly locations, even small and At that point, managers can think about iden-
midsized manufacturers can have difficulty tifying the root cause of the problem and how to
instructions are logged keeping everyone in their organizations on the correct it. Say, for example, an operator was using
same page. If a new standard or regulation affects a machine incorrectly because the work instruc-
into the system, the your assembly process, can you be certain every- tions were out of date. The CAPA module can
one gets the message? If an assembly-related trigger a request to update the instructions in the
software alerts every defect is reported in the field, can you be sure the document management module. The “owner” of
mistake isn’t repeated? the document would know to update the instruc-
operator to the new You can, with web-based enterprise compli- tions and get any necessary approvals.
ance and quality management software, says When the updated instructions are logged into
procedures. Nikki Willett, vice president of marketing and the system, the training and certification module
regulatory affairs at is alerted to ensure that every operator who uses
Pilgrim Software in that machine knows the new procedures. This
Tampa, FL. Pilgrim’s can be as simple has having each operator sign
product consists of off on the new instructions. “Or, you may want to
seven interrelated, have the manager confirm that the operators have
customizable modules read it,” says Willett. “Operators may have to go
that cover audit man- through a checklist or take a small exam. They
agement, training and may even need classroom or online training.
certification, calibra- ...And because our software can be integrated
tion and maintenance, with other business software, employee records
s u p p l i e r q u a l i t y, can be automatically updated to reflect that they
document manage- have completed the training, which they may
ment, complaint han- need for their job certification.”
dling, and corrective Perhaps the cause of the problem wasn’t an
and preventive action outdated work instruction, but a machine that
Web-based enterprise (CAPA) management. A key feature is the soft- was out of specification. The calibration and
compliance and quality ware’s ability to integrate with other software, maintenance module can tell management when
management software can such as enterprise resource planning systems, the machine was last calibrated or serviced, and
help assemblers address
manufacturing execution systems, product life it can notify maintenance personnel to make an
quality problems whenever
cycle management software, human resources adjustment or replace a part.
and wherever they occur.
Photo courtesy CEA software, and call-center systems. If the problem was faulty parts from a supplier,
Technologies Inc. The top priority of any manufacturer is to the supplier quality module gets triggered. “That
address quality problems whenever and wher- could impact the rating of the supplier,” says Wil-
ever they occur. The CAPA management module lett. “You may want to requalify that supplier. You
captures these problems from multiple sources. may even want to change suppliers.”
“It can be a customer complaint,” says Willett. “It If ISO or FDA certification is necessary, the
For reprints of this can come from your MES, because of a problem audit management module can help engineers
article, please contact on the shop floor. It may be an issue with incom- prepare for audits and deal with their findings.
Cindy Williams at ing parts from a supplier. It may come from a “Auditors will come through with their ques-
williamsc@bnpmedia.com piece of equipment that’s out of spec.” tions and checklists,” says Willett. “They may
or 610-436-4220 ext. 8516. When a problem is identified, a number of find some issues and...make recommendations
decisions need to be made quickly. Does the pro- for improvement. Engineers can use the soft-
duction lot need to be contained? Has it already ware to enter their plans for correcting those
entered the distribution pipeline? Software tracks issues. Some of the auditor’s findings may be so
■ By John Sprovieri it down. In the case of a medical device, the soft- critical that engineers may want to escalate to a
Editor ware can also generate an electronic report for CAPA.” A
www.assemblymag.com August 2009 / ASSE M B LY 9
WE FED IT
System Feeds, Assembles Springs

䡲 By John Sprovieri
Editor
S
prings are tough to feed. They’re flexible, surfaces. The parts are threaded onto a rod and
and they tangle easily. Centricity Corp. has secured by a series of alternating jaws. Parts are
developed a machine, called the Versa-Stack, free to travel down the rod as the jaws open and
that overcomes the challenges of feeding and close. This maintains control of the part at all times.
assembling springs and other tubular parts. There is no chance for parts to flip, shingle or fall
Recently, the machine was put to the test. It had off. The Feedscape does not require a vibratory in-
to stack three cylindrical parts—a ring formed from line track, and tooling is inexpensive and flexible.
steel wire, a metal tube, and a small or large coil As the dial indexes clockwise to the 11:00
spring—and place the stack into a larger assembly. position, a ring is fed from the bowl to a Feedscape,
The OD of each part was approximately 0.15 inch; which drops it onto a pin. The dial then indexes to
the ID was 0.1 inch. the next position, where the tube is dropped onto
The Versa-Stack consists of a vertically the same pin. Next, the dial indexes to the final
oriented servo-driven rotary indexer fitted with position, where the small spring is dropped onto
a custom dial plate. Mounted radially around the the pin. If the assembly requires the large spring,
edge of the plate are 35 replaceable pins. Above the first spring feeder is bypassed and the second
the plate are two vibratory bowl feeders and two feeder is activated.
spring feeders fitted with Centricity’s Feedscape The stacks are held in place by an integrated
systems. retaining system until they reach the 6:00 position.
The Versa-Stack consists of a servo- The Feedscape is designed to feed parts with At that point, the stack is threaded onto another
driven rotary indexer with a custom dial a high diameter-to-length ratio, such as washers, Feedscape mechanism, which passes it off to a
plate. Mounted radially around the edge retaining rings, wave washers, Belleville springs, robot at a rate of 15 per minute.
of the plate are pins for holding tubular seals and bearings. Instead of handling parts by For more information, call 330-545-5624 or
parts. Photo courtesy Centricity Corp. their outer surfaces, it handles parts by their inside visit www.centricity.net.
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Automotive Supplier Rides
the Winds of Change
䡲 By John Sprovieri
Editor
N
ot that long ago, MasTech Manufacturing in Manistee, MI, was
riding high. A supplier of conveyors, material handling equip-
ment and welding cells for the automotive industry, the com-
pany had won some major contracts, including lines at Freightliner in
Cleveland, NC, and BMW in Spartanburg, SC.
But then the automotive industry hit the skids. MasTech’s work-
force went from approximately 50 people in mid-2008 down to just
three. If the company were to survive, it would have to diversify. So,
when Reno, NV, startup Mariah Power went looking for a manufac-
turer to build its new wind turbine for residential and light commercial
use, MasTech leapt at the opportunity.
It signed a contract with Mariah Power in December 2008, and be-
gan converting its 30,000-square-foot facility to make the turbine, a
vertical-axis design called the Windspire. All totaled, MasTech spent Since April, MasTech has been assembling 100 turbines per month—a
some $1.5 million on new equipment. “We built robotic [and] manual number that could increase to 1,000 per month within a few years.
Photo courtesy Mariah Power
welding tools,” says John Holcomb, MasTech’s general manager. “We
built custom material handling equipment and racking. We bought The turbine’s aluminum airfoils are produced by Whitehall Industries
new machine tools.” Inc. in Ludington, MI. Steel parts come from Alro Steel Corp. in
“It’s been our desire since Day 1 to Jackson, MI. The inverters are assembled by Amptech Inc. in Free
Soil, MI. Boxes and crates are made by Norton Packaging Corp. in
make the largest economic impact in Grand Haven, MI. At least three other Michigan companies are also
part of the supply chain.
the smallest geographical area.” “It’s been our desire since Day 1 to make the largest economic impact
in the smallest geographical area,” says Holcomb. “The only components
—John Holcomb, MasTech that come from outside the United States are the rare earth magnets, which
come from China, but that’s where neodymium is mined.”
Production began in April. Since then, the company has been Holcomb emphasizes that his company’s turnaround should not be
assembling 100 turbines per month—a number that could increase to considered unique. “We’ve proven that, given the right tools and the right
1,000 per month within a few years. MasTech has shipped Windspires attitude, American workers can compete in the global market by supplying
throughout the United States, as well as internationally, including not only a cost-effective product, but a superior product,” he says. “Anyone
Israel, Denmark, France and the Netherlands. can do it. We have the technology. If we reapply it and leverage it in new,
The company has hired back all the employees who were laid off, innovative directions, we can compete with anybody.” A
and even added a few more. By the end of 2009, the company could
have a workforce of 75 to 80 people. “By the end of next year, we Editor’s note: With all the news of bailouts, layoffs and plant
hope to employ approximately 120 people,” says Holcomb. “If we closings, it’s all too easy to think every manufacturer is stuck in the
start selling more overseas, we could potentially have 500 to 600 jobs doldrums. In fact, there’s plenty of good news in manufacturing—if
in five years.” you take the time to look. “Moving Forward” is dedicated to new
The Windspire is 30 feet tall and 4 feet wide. It includes a high- or expanding assembly plants. If you know a facility that’s opening,
efficiency generator, an inverter, a hinged monopole and a wireless growing, investing in new equipment, or simply going great guns
performance monitor. The 1.2-kilowatt machine will produce approxi- while everyone else is treading water, we’d like to hear about it. Send
mately 2,000 kilowatt-hours per year in winds averaging 12 mph. an e-mail to John Sprovieri, editor of ASSEMBLY, at sprovierij@
From the start, MasTech included local suppliers in the endeavor. bnpmedia.com, or call 630-694-4012.

2 people. 1 tool. Infinite configurations.
With the Arlink® 8000 workstation, the possibilities are mind-boggling. A couple
1
of people with a Phillips screwdriver can build exactly what you need. The unique
Full Adaptability Definite Positioning System®, dozens of footprint configurations, and Starter and
The Arlink 8000’s
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Adder modules let you easily set up a workstation
System allows easy, for any application. And when it’s time for a change,
secure placement
you’re done in a few minutes. It’s that simple. It’s that
and reconfiguration
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Experience a detailed, interactive overview of the Arlink 8000 workstation’s

innovative, time-saving features. Visit www.arlink6.listaintl.com
Assembly Lines
Inventions
Forecasts
Mergers
New facilities
Deere & Co. bus bar attachment methodology: a
Group Launches Wind Planning Russian point-to-point soldering process that
uses a lead-free solder paste and
Energy Database Expansion flux mixture to attach string ribbon
MOLINE, IL—Deere & Co. material to silver bus bars during so-
says it is prepared to “significantly lar module assembly.
expand its farm, forestry and con- In addition to eliminating the
struction operations in Russia,” as need for precoating with a liquid
part of the company’s long-term flux, the process creates a robust
commitment to the region. solder joint with minimal micro-
The remarks came during a re- crack formation. The result is an
cent Russia-USA Business Forum increased lifespan for the solar
in Moscow, which took place at modules in which it is used.
the same time President Obama
was meeting with Russian presi-
dent Dmitry Medvedev.
“We share the vision that Rus- Kyzen Opening
sia can make a significant and sus- Malaysia Office
tainable contribution to help meet NASHVILLE—Electronics
the world’s growing demand for cleaning products manufacturer
food, energy and forest products,” Kyzen is opening a new sales and
says Deere CEO Samual Allen. support facility in Penang, Malay-
“John Deere is working to expand sia, as part of an ongoing effort
The Great Lakes WIND Network has created an online database to its Russian manufacturing capac- to increase the company’s market
help wind energy companies locate suppliers and other renewable
ity for agricultural equipment by share in the Asia-Pacific region.
energy organizations.
early 2010. Ultimately, with the “The possibility of a Kyzen fa-
CLEVELAND—The Great Lakes WIND Network, an interna- support of the government of the cility in Southeast Asia has been
tional wind energy supply chain advisory group, has launched a new Russian Federation, Deere could under consideration for some
web-based WIND Energy Supply Chain Database and Mapping envision a series of significant time,” says Kyzen vice president
System, available online at http://maps.glwn.org/wind/, to promote investments over the next five to Tom Forsythe. “Malaysia is an im-
the growth of the wind power industry. seven years in expanded capacity portant hub for high value-added
The site features an interactive map and a searchable wind supply for manufacturing and supporting electronics and other high-tech-
chain database containing the profiles of more than 1,000 manufac- all types of Deere equipment.” nology manufacturing with a busi-
turers and organizations in the United States, Canada and Mexico ness friendly environment and,
that actively serve the emerging wind industry. most importantly, with a highly
Designed to facilitate customer-supplier relationships, the sys- educated, dedicated work force.”
tem quickly connects manufacturers and suppliers with OEMs, EFD Inc. Wins Founded in 1990, Kyzen pro-
economic development officials, consultants and other wind power Solar Award vides cleaning products to a wide
supply-chain partners. EAST PROVIDENCE, RI— range of customers, including those
“The wind energy sector is the fastest growing industry in North Dispensing equipment manufac- in the electronics, metal finishing,
America. By linking buyers, sellers and other industry partners, we turer EFD Inc., a subsidiary of medical device, semiconductor and
believe this system can be a catalyst for business expansion, invest- Nordson Corp., has won the 2009 optical components industries.
ment and new jobs,” says network director Ed Weston. “We are very International Solar Cell Award for
excited at the prospect of being able to service our global network best technical product.
with a single site that supports supply chain needs.” Presented at the 2009 InterSolar
Access to the site is free. To register with the database, visit Exhibition in Munich, Germany, the Volvo Kicks Off
www.glwn.org, select “Get Listed,” and complete a Wind Capabili- award comes in recognition of the Fuel Cell Initiative
ties Profile to start the registration process. company’s new PV cell ribbon and GOTEBORG, Sweden—Volvo

group is teaming up with Midroc end of the study period. The U.S. manufacturer Stäubli Robotics In all, some 24,000 buyers
New Technology, the OCAS re- market will continue to be the is teaming up with the engi- were on hand for the co-located
search center in Belgium and the strongest, accounting for slightly neering and integration compa- MD&M East, EastPack, Automa-
Swedish Energy Agency to devel- over a third of total demand. ny Rixan Associates Inc. to co- tion Technology Expo East, Green
op and produce a new generation In addition to responding to an ordinate activities in the areas Manufacturing Expo and Atlantic
of fuel cells for possible use in ev- eventual turnaround of the current of marketing and sales, with Design & Manufacturing shows
erything from trucks to boats. housing crisis, the U.S. market is also an emphasis on robotic auto- held at the Javits Convention Cen-
As part of the initiative, the three expected to benefit from the introduc- mation services, engineering ter in June.
members are forming a new joint- tion of new and improved products, services, components, software “A number of our exhibitors
venture company called Powercell such as cordless electric tools. and training. expected that attendance would
Sweden AB, based in Gothenburg, Freedonia researchers say there “We are building the future by be down because of the current
Sweden. The $25 million effort is will also be healthy demand in bringing two world-class orga- state of the economy,” says Canon
expected to create some 100 new Brazil, Russia, India and China, nizations together in forming a Communications CEO Charles G.
jobs over the next three years. with demand in China and India strategic partnership. This part- McCurdy. “Instead, the success of
rising about 6 percent annually in nership will reinforce our mutual this event has generated consider-
the course of the study period. customer-centric commitment in able optimism among them about
For more on the study, visit providing first class service and the enduring business vitality of
Interior Components www.freedoniagroup.com. support to our customers,” says key advanced manufacturing seg-
Company Expanding Stäubli Robotics division manager ments, most notably medical de-
in Midwest Joe Gemma.
“We are excited about this new
vices.”
As further evidence of this fact,
VALPARAISO, IN—UGN Inc., Nordic Windpower partnership,” says Rixan President McCurdy says about two-thirds of
a manufacturer of interior trim Secures DOE Loan Stephen Harris. “Rixan needed ro- the event’s 1,000 exhibitors have
products for the automotive indus- BERKELEY, CA—The U.S. bots with higher payloads, faster already contracted for space in the
try, will invest about $3 million to Department of Energy has ap- cycle times and robots that had 2010 show.
expand its production capacity in proved a $16 million loan to help more application-specific features. “The MD&M East Show al-
northern Indiana. The company Nordic Windpower USA Inc. Stäubli robots fulfill those needs lowed us to land more than 90
says it will also add another 100 expand its production facility in and will provide our customers leads, of which 75 percent or more
employees to its payroll by 2014. Pocatello, ID. with leading-edge technology, have immediate needs for our
“UGN continues to grow and The loan is being supported high reliability and a worldwide products and services,” says Ken
celebrate successes in a very chal- through the 2009 American Re- support network.” Jenkins, president of Ohio-based
lenging economic environment,” covery and Reinvestment Act, mold maker Pleasant Precision
says company CEO Randy Khalaf. signed into law by President Inc. “I have displayed at more
“Our Valparaiso facility is seeing Obama in February. than 15 trade shows in the past
incredible expansion and is well Nordic Windpower manufac- Assembly Event 10 years, and the MD&M East
positioned with new products and tures two-bladed, utility-scale wind Records Strong Show provided more substantial
technology to see further growth
once the global economy starts to
turbines featuring a flexible “teeter-
hub” that helps dissipate the force
Attendance leads than all of the other shows
together.”
show signs of recovery.” of turbulent winds that would oth- NEW YORK—Despite a chal- For more on Canon Commu-
Founded in 1986, the company erwise cause undue wear on the lenging economy, Canon Com- nications, which also organizes
is adding 10,000 square feet of system’s drive train. As part of the munications says attendance was the Assembly Technology Expo
manufacturing space to accommo- expansion, Nordic plans to add an- up 3 percent at its recent assembly in Rosemont, IL, sponsored by
date a new contract to produce in- other 75 employees to its payroll. and medical device trade event in ASSEMBLY magazine, visit
terior components for both luxury “Nordic’s expansion will create New York. www.cancom.com.
automobiles and SUVs. The com- new and skilled green jobs to boost
pany also provides components the economy and help meet America’s
for small trucks. growing energy needs with clean
wind power,” says Tom Carbone,
CEO of Nordic Windpower. “We
appreciate DOE’s vote of confidence
Power Tool in our innovative technology and our
Demand Rising business model.”
CLEVELAND—Despite the
current recession, global demand
for power tools is expected to in-
crease 7 percent annually through Stäubli, Rixan
2013, according to a recent study Associates
by The Freedonia Group.
Total annual demand is expect-
Joining Forces
ed to be about $29 billion by the DUNCAN, SC—Robotics Canon Communications’ trade show in New York continues to grow,
despite the tough economic climate.

Assembly in Action
Single-Cable Camera
Maximizes Efficiency
C
omau Group, a subsidiary of stored into the system’s memory, which
Fiat Spa, builds automated allows the system to recognize the tar-
production machines for a get part and maneuver a servo-actuated
wide range of customers, in- manipulator to pick, place or work on
cluding those in the automo- that object.”
tive industry. The company To make the system as effective and
also manufactures turnkey automated efficient as possible, Comau engineers
assembly systems, robots, weld guns, wanted to reduce the amount of cabling
conveyors, recognition software and connecting the robot-mounted camera
other automation components. to the robot controller. Standard GigE
Recently, engineers at the company’s cameras require three cables: one for
North American headquarters in South- communications, one for power and
field, MI, developed what they call one to trigger the camera to take a pic-
VersaVision II software as an upgrade ture. Three cables means three times
to the company’s the opportunity for failure in a single
existing robotic camera application.
guidance systems.
The new software Comau engineers wanted to reduce
allows a robot to
both pick up parts the amount of cabling connecting
and then position
them in space us- the robot-mounted camera to the
ing a single ma-
chine-vision cam-
robot controller.
era, as opposed to “To make our robotic guidance sys-
multiple cameras. tems as reliable and cost-effective as
The software can possible, we wanted to take our de-
be used with any sign one step further,” says Comau
GigE camera or robotics and vision products manager
robot currently on Tony Ventura. “Not only did we need
the market. By re- to reduce the number of cameras in
By eliminating the need for any ducing the number of cameras, the sys- our systems, we wanted to reduce the
additional cables, the camera tem helps assemblers reduce costs. chances of system failure associated
minimizes the risk of cable fatigue and “The VersaVision II program pro- with cabling. The more cables located
greatly improves the integrity of the
vision system. vides our robots true visual recogni- on a robot, the higher the risk of cable
tion,” says Comau product develop- failure.”
ment engineer Max Falcone. “The To solve the problem, Comau in-
software emulates the visual cortex of corporated a TXG camera with power
the human brain, teaching the system over GigE cabling from Baumer Ltd.,
For reprints of any to recognize an object the same way a manufacturer of sensors, motion-
Assembly in Action article, you would teach an infant. We show control equipment and machine vision.
please contact Cindy Williams the system an object by taking a picture In the Comau application, the camera
at williamsc@bnpmedia.com of the object and naming it. All of the includes a specially developed indus-
or 610-436-4220 ext. 8516. information pertaining to that object is trial power injector module or Ethernet

off parts that are incorrectly To develop the application, Rixan
oriented and allow through engineers first used the Melfa-Vision
only those parts that are po- software to calibrate the robot in rela-
sitioned correctly. tion to the feeder. They then put a part
Historically, because of in the robot gripper and “jogged” the
the various hard-tooled robot over to the feeder where it set the
orientation features that part down on the plenum. In this way
are required, this kind of engineers “taught” the robot to pick up
equipment has been very the part in this orientation and at this
part-specific. However, the point on the plenum.
robotics company Rixan Once the robot had been taught how
Associates Inc. has devel- to pick up the part, Rixan’s engineers
oped a new flexible vibrato- used the Cognex camera’s PatFind
The new software allows a robot to both pick up parts and ry bowl feeder that includes object-location tool to draw a rectangle
position them in space using a single camera. a robot and machine vision around the part on the screen, thereby
system to orient multiple allowing the vision system to automati-
switch that provides power down a Cat6 parts using a single system. cally recognize the part as it moves
Ethernet cable at distances up to 100 Rixan originally developed the across the plenum.
meters. By eliminating the need for any system to load dozens of different In operation, when it sees a part, the
additional cables, the Power over GigE aerospace fasteners into a press, a system first sends a signal to stop the
Camera minimizes the risk of cable fa- task that was previously
tigue and greatly improves the integrity performed by hand and
of a vision system. would have otherwise
According to Falcone, Comau also required installing many
liked the camera because of its robust different feeders to
design and performance features. “The automate.
camera is neat, complete and well engi- The new system em-
neered. The lock-style connections are ploys a vibratory bowl
strong, reliable, industrially accepted feeder that randomly pres-
M8 connectors. The integrated UV ents the parts to the vision
filter mounted in front of the camera’s system, which in turn,
face eliminates the need to buy and in- stops the feeder when it
stall a separate filter to show true col- sees the correct part in
ors. This high-quality camera allows us the correct orientation so
to provide our customers with an over- that a robot can load the
all lower cost system,” he says. part into the press. The The system employs a vibratory bowl feeder that randomly
For more on machine vision, visit parts are presented on a presents the parts to the vision system, which in turn, stops the
feeder when it sees the correct part in the correct orientation.
www.baumerelectric.com/usa or call semitransparent, backlit
800-937-9336. plenum, so the vision sys-
For more on automation, call 248- tem can easily identify them. The parts feeder. After the feeder has stopped, the
353-8888 or visit www.comauinc.com. that are not picked automatically recycle vision system acquires one last image to
into the bowl. The result has been a 20 determine the exact position of the part
percent increase in productivity and one and calculate its angle of presentation.
Vision Enables Feeder to less operator to tend the press. The robot then moves to the location
Critical to the success of the system of the part, twists its wrist to match the
Handle Multiple Parts has been its In-Sight 5401 vision sys- part’s orientation, picks up the part and
T raditional vibratory bowl feeders use tem from machine vision manufacturer sends a signal to restart the feeder.
a helical shelf-like inclined ramp Cognex Corp., which is integrated with Most of the parts in the aerospace
winding up from the bottom of a bowl an RV-6SL-S11 robot and Melfa-Vision fastener application are symmetrical
to a discharge passageway. The pas- software from Mitsubishi Electric. top to bottom so they can be identified
sageway’s reciprocating motion pushes Rixan chose the In-Sight 5401 because from their silhouette alone. However,
the parts up the ramp. Obstructions, of its processing power and the fact that in those instances where a part has two
cutouts and other orienting devices are it can acquire up to 60 complete eight- distinct sides, the Cognex PatMax tool
arranged along the passageway to topple bit images per second. can be used to recognize which side is

Assembly in Action
up. Top-down lighting is used options like speed enhance-

for parts in which pattern ment, next-generation un-
recognition is required. White derstencil cleaning technol-
light is used for some parts, ogy and automatic board
while glare-free polarized support, as required.
lighting is used for others. “It’s no coincidence that
“A key to the success of DCI has been named to
this application is the ease-of- Fortune Small Business
setup, accuracy and reliability magazine’s list of the fastest
of the Cognex In-Sight vision growing small companies
sensors,” says Rixan Associ- for the past two consecu-
ates President Stephen Har- tive years,” says DCIs vice-
ris. “The PatMax tool that we president of business devel-
use to recognize part features opment Jay Gillam. “When
is much faster and more ac- your top priority is ensur-
curate than other comparable ing your customers receive
industry tools that we have outstanding service and su-
seen. The easy integration be- perior quality products on
tween Cognex vision sensors time every time, business
The screen printer’s scalability means it can be modified to meet DCI
and Mitsubishi robots drasti- Inc.’s future manufacturing needs as well as those in the present. success is inevitable. Our
cally reduces the amount of addition of DEK’s Horizon
time required to develop vision-enabled system’s quick setup and changeover 03i is just one more example of this
robot applications and in most cases times, as well as its new HawkEye print commitment.”
eliminates the need for writing a single verification inspection feature. For more on custom electronics man-
line of code.” “We evaluated several screen printing ufacturing, call 888-824-9412 or visit
For more on machine vision, call 508- systems,” Morgan says. “The capability www.dciincorporated.com.
650-3000 or visit www.cognex.com. of DEK’s Horizon 03i coupled with For more on screen printing systems,
For more on parts feeding and the staff’s depth of knowledge and visit www.dek.com.
automation, call 937-438-3005 or visit process expertise made our decision an
www.rixan.com. easy one. With the Horizon platform’s
new scalability, future-proofing and Workbenches Harmonize
ability to customize, we can modify
With Design Goals
Screen Printer Adapts to the system to meet our manufacturing
Changing Needs requirements as our business changes
and grows.” O ne of the goals of the school of
architecture at the University of
D CI Inc., in Olathe, KS, designs and DEK’s entire

manufactures electronics compo- Horizon line of
nents and subassemblies for custom- screen printers
ers in a wide range of industries. The includes mo-
company specializes in the design and torized sten-
manufacture of specialized custom liq- cil alignment,
uid crystal displays, light emitting di- fast product
ode displays and operator interfaces. changeover, 2.0
Recently, the company expanded its Cpk print pro-
electronics manufacturing capacity by cess capability
implementing a new Horizon 03i fully and Six Sigma
automatic screen-printing system from production per-
electronics assembly equipment manu- formance. The
facturer DEK USA Inc. system’s In-
According to DCI chief operating stinctiv V9 user
officer Mike Morgan, the company interface allows
went with the Horizon 03i because of manufacturers When the school of architecture at the University of North Carolina went
its high print quality and ease of use. to seamlessly in- shopping for new workbenches, it ended up going with a set of stations
Morgan says his company also likes the tegrate advanced from industrial workstation manufacturer Lista International.

LMS Move It Island Ad - Assembly.ai 5/30/2007 12:01:35 PM
North Carolina in Charlotte is to supply these workbenches within a we didn’t use it by the given deadline,
help students “apply strategic think- very tight window of time—about we’d lose it. Fortunately Lista came
ing to environmental problems.” It eight weeks to be exact. This through, not only on time, but with
was therefore only natural that when included about one week for delivery completely assembled products.
the school needed a new set of work and installation,” he says. “At the Many of the other bidders were
desks, the students should take part university level, we call the money delivering only parts. Lista provided
in the selection process. that’s left over from the annual a ready-to-use solution.”
“Our existing desks had worn out budget ‘one-time money.’ This is For more on workstations, call 800-
their welcome,” says Ken Lambla, what we were working with, and if 722-3020 or visit www.listaintl.com.
dean of the university’s college of
arts and architecture. “The old desks
were custom-designed and custom-
made when we first occupied our
building in 1991. They may have
been sufficient then, but today they
didn’t offer the kind of flexibility the
students’ work demanded. Not only USING TECHNO AUTOMATION
were the dimensions and ergonomics
insufficient, but they were lacking in
many key areas of functionality: no
power supplies, no wheels for mobil-
ity, inadequate display surface, and
S
serious storage limitations.”
S E RIE
Ultimately, after consulting with a VB1
AG ER Stock Lengths Up To 3 Meters
VOY
student-run focus group and putting
Custom Lengths Up To 6 Meters
the project out for bid, the college
All Steel Profile Rail For High Load Capacity
replaced more than 200 of its old 50mm Wide Steel Reinforced Belt For Heavy Loads
desks with a set of Arlink worksta-
tions from industrial workbench and
cabinet manufacturer Lista Interna- VISIT OUR DOWNLOAD 3D MODELS
tional Corp. WEBSITE REQUEST FREE CATALOGS
at www.technoautomation.com
According to Rich Preiss, the school’s
director of laboratories, the school GANTRY TABLE
chose the Arlink workbenches because XY or XYZ 12 Series
they were rugged, functional and aes- Glue Dispensing
thetically pleasing. Assembly
Lambla adds that Lista was also very Inspection
responsive in terms of meeting the Pick & Place
school’s particular needs.
“Being architects, we’re pretty
detail driven,” he says. “We needed
a company that was going to work
with us on the exact details of fabri-
cation as it relates to the experience
we’ve had over the last 15 years.
Lista brought a lot of knowledge to AFFORDABLE
QUALITY
the table and demonstrated an ability
to create custom application-specific
solutions.”
Lambla adds that the company was
able to work within a narrow time
frame, another reason the college went
Techno Inc. 1-800-819-3366
SINCE 1986
with the Arlink desks. Linear Motion Systems www.technoautomation.com
“We needed somebody who could
ASSEMBLY Medical Device Assembly
Better One or
Better Two?
Ophthalmic device
A
s most people age, they become Approximately 50 percent of
wiser. But, gradual vision loss all adults in the United States don’t
manufacturers keep an eye on is something that even the
smartest people in the world
have 20/20 vision, because they are
nearsighted, farsighted or have an
new technology. can’t avoid. That simple fact astigmatism, which is an irregular curve
of life is good news for the of the cornea. By 2020, the number of
ophthalmic device industry. people who are blind or have low vision
Cataracts, glaucoma, macular degen- is projected to increase dramatically.
eration, presbyopia, diabetic retinopa- “Blindness or low vision affects 3.3
thy, posterior uveitis and other vision- million Americans age 40 or over . . . and
related conditions make ophthalmology this figure [will] reach 5.5 million by the
year 2020,” says Elias Zerhouni, M.D.,
director of the National Institutes of
Health (Bethesda, MD), which operates
the Eye Disease Prevalence Research
Group and the National Eye Institute.
“As our population lives longer, eye
disease will be an ever greater concern.
Low vision and blindness increase
significantly with age, particularly in
people over age 65.”
A recent study conducted by RTI
International (Research Triangle Park,
NC) and the Centers for Disease Control
and Prevention (Atlanta) predicts there
will be a huge demand for ophthalmic
devices over the next four decades.
“The aging U.S. population will lead to
a large increase in early and advanced
age-related macular degeneration,”
claims David Rein, a senior research
Because of the aging population, there will be one of the most dynamic market seg- economist at RTI.
a huge demand for ophthalmic devices over the ments in the medical device industry. “By 2050, the number of people with
next four decades. Photo courtesy Carl Zeiss An aging population, proposed fed- early age-related macular degeneration
Meditec AG
eral healthcare reform and an increas- will double to more than 17.8 million,”
ing number of elective surgeries, such Rein points out. At the same time, he
as Lasik treatment, is creating a huge expects the number of cases of diabetic
demand for diagnostic instruments, sur- retinopathy, which is the leading cause
gical equipment, lasers, intraocular lens of blindness among working-age adults
By Austin Weber implants, shunts, artificial retinas and in the United States, to increase from
Senior Editor other products. 5.5 million to 16 million.
“The good news is that medical
technologies are changing rapidly,”
says Rein. “Ten years ago, there were
no treatments for age-related macular
degeneration. With luck, tomorrow’s
discoveries will lead to far greater
reductions in visual impairment and
blindness.”
According to MedMarket Diligence
LLC (Foothill Ranch, CA), the
worldwide ophthalmic products market
exceeds $22 billion and is growing at
more than 10 percent annually. The
industry is dominated by several
major players, such as Abbott Medical
Optics Inc. (Santa Ana, CA), Alcon
Laboratories Inc. (Fort Worth, TX),
Bausch & Lomb Inc. (Rochester, NY)
and Carl Zeiss Meditec AG (Jena, A wide variety of diagnostic instruments are used by ophthalmologists to examine patients, such as
Germany). However, numerous small slit lamps. Photo courtesy National Eye Institute
start-up companies specialize in niche and scanning laser tomography are imaging devices called OCT (optical
segments, such as cataract, corneal or both giving increasingly sharper reso- coherence tomography) that allow us to
refractive surgery. lution of the microscopic structures of create microscopic images of structures
No matter the size of the company, the eye, allowing for a more detailed inside the eye that were never before
ophthalmic manufacturers are focusing view of pathology. visible,” adds John Hovanesian, M.D.,
their efforts on making surgical proce- “This has also allowed us to an ophthalmologist at Harvard Eye
dures faster, easier, more accurate and visualize the relationship between the Associates (Laguna Hills, CA) and
more affordable. There’s also a growing different regions of the eye in a way a clinical instructor at UCLA’s Jules
trend toward drug-device combination we have never been able to before, Stein Eye Institute (Los Angeles). “This
products. without having to resort to intravenous greatly aids in diagnosis of conditions
dye injection,” explains Shatz. “More like diabetic eye problems, eye tumors
Diagnostic Tools doctors are adopting technology that and macular degeneration.”
Traditionally, the ophthalmic indus- allows us to image the back of the eye An OCT allows an ophthalmologist
try is divided into two main segments: without the need for dilation.” to construct three-dimensional images
diagnostic instruments and surgical “We now have incredibly precise of living eye tissue with better resolution
devices. Diagnostic instruments are
used by ophthalmologists to examine
their patients. They include refractors
(the “better-one, better-two” device
that’s used in conjunction with an eye
chart), slit lamps (an upright micro-
scope equipped with a bright light) and
tonometers (a device that measures eye
pressure).
Ophthalmologists are always
looking for equipment that makes them
better clinicians. They want instruments
that provide information that allows
them to make better diagnoses and
more efficient treatment decisions in a
patient-friendly manner.
“The latest trend is toward non-
invasive diagnostic imaging,” says
Andrew Shatz, M.D., an ophthalmol- The human eye is a complex, delicate organ. Common back-of-the-eye diseases include
age-related macular degeneration and glaucoma. Illustration courtesy American
ogist at the Woolfson Eye Institute
Academy of Ophthalmology
(Atlanta). “High-speed ultrasound
Medical Device Assembly
than a traditional MRI scan. the world’s first noninva-
Better yet, the procedure sive early detection device
can be performed in a for cataracts, the leading
doctor’s office instead of a cause of vision loss world-
hospital. wide. The new device is
Today’s new breed of based on a laser light tech-
diagnostic instruments use nique called dynamic light
state-of-the-art technology scattering (DLS).
to objectively measure and It was initially devel-
quantify vision disorders. oped to analyze the
For instance, engineers at growth of protein crystals
Optos Inc. (Marlborough, in a zero-gravity space
MA) recently developed environment. The table-
a new type of imaging top DLS device is used
device that provides an to detect the earliest dam-
ultra-widefield view age to lens proteins, trig-
of the retina. It allows gering an early warning
ophthalmologists to see This telescopic implant is 4 millimeters long and contains two wide-angle glass for cataract formation and
lenses. It is designed to treat age-related macular degeneration. Photo courtesy
more than 80 percent of VisionCare Ophthlamic Technologies Inc. blindness.
the retina, compared to a “Much of the work [in
traditional camera that provides a much Researchers at the National Eye Insti- the diagnostic instrument field] is going
narrower view—about 11 percent. The tute (Bethesda, MD) and the National into finding ways to treat presbyopia to
device uses scanning coherent laser Aeronautics and Space Administration enable people to get rid of their reading
light rather than full spectrum white (NASA, Washington, DC) recently glasses,” says James Ohneck, CEO of
light that’s typically used by cameras adapted a compact fiber-optic probe Oculatek Inc. (Cleveland). The start-up
and other forms of ophthalmoscopy. developed for the space program into company has developed a transscleral
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light therapy system that uses a low them from quickly ramping up produc- assembled in clean rooms. Large
level of infrared light at a specific wave- tion. For instance, Oculatek’s device is manufacturers, such as Alcon, have
length. “It helps strengthen the ciliary still undergoing trials with the FDA. If recently been focusing their efforts on
muscle, which weakens as the eye ages approved, it won’t be readily available ergonomics and automation. Alcon’s Fort
and is one of the factors that leads to to ophthalmologists for several more Worth plant recently celebrated its 50
the eye’s inability to accommodate,” years. anniversary, and the company is currently
Ohneck points out. “The challenges around new devices building a new facility in Singapore to
“It is therapy, not surgery,” adds are regulatory in nature, such as supply the fast-growing Asian market.
Ohneck. “The patient has several short getting FDA approval and validating “In our more manual assembly areas,
therapy sessions where they look into the efficacy through clinical trials,” we have invested in adjustable work-
a binocular while the eye is dosed says Ohneck, who holds a degree in stations and eliminated microscopes
with infrared light. The treatment does electronic engineering. “This takes time to make our operators more comfort-
not harm the eye and there is no pain and money. Investors are reluctant to able,” says Melissa Mota, a company
associated with the procedure. It’s unique put money into products that don’t have spokesperson. “In addition, we have
because it is the first device of its kind to the trials, so it’s a chicken and egg; invested heavily to automate mid- and
therapeutically treat presbyopia without you need money to do clinicals, but higher-volume operations and products.
an invasive surgical procedure. Newer you can’t get it until the clinicals are Our focus has been on advancing our
technologies being developed involve completed.” assembly processes to be flexible with
implanting special lenses through a To reduce costs, many start-up high-mix automation, in order to satisfy
surgical procedure or modifying the manufacturers outsource assembly to increasing demand for our products.”
shape of the eye to adjust vision.” third parties. For instance, Oculatek is
Even noninvasive ophthalmic pro- working with Valtronic Technologies Implantable Devices
cedures must be cleared by the U.S. Inc. (Solon, OH). That allows Ohneck One of newest technological advanc-
Food and Drug Administration (FDA, and his colleagues to focus their es on the surgical side of the ophthalmic
Washington, DC), which often hinders attention on product development. device industry is the correction of pres-
start-up manufacturers and prevents Ophthalmic devices are typically byopia, which affects 90 million people

asb08094dymax.indd 1 www.assemblymag.com August 2009 / ASSE B LY 25
7/14/09M10:20:55 AM
Medical Device Assembly
An OCT allows ophthalmologists to construct three-dimensional images of

living eye tissue with better resolution than a traditional MRI scan. This fiber-optic probe uses NASA-developed technology to detect
Photo courtesy Carl Zeiss Meditec AG cataracts. Photo courtesy National Eye Institute
in the United States, with multifocal technologies, all aimed at achieving the will overtake laser vision correction as
and accommodating implants. “These holy grail of ophthalmology. the primary means of correcting vision
not only improve distance vision with- “The new revolution is almost at in the next five to 10 years.”
out glasses, but also decrease the need hand,” claims Shatz. “Improved lens and Intraocular lenses (IOLs) are
for readers,” says Shatz. “This market cataract surgery technology, in combi- typically made of either acrylic or
has been heating up over the last few nation with the baby-boomer generation silicone. Early versions were made of an
years. What has started out with three now developing cataracts, has created acrylic polymer called PMMA, which is
competing lens models will [eventu- the perfect breeding ground for pres- what led to the discovery of using IOLs
ally] blossom to 10 or more different byopic lens implants. This technology in cataract surgery.
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26 ASSEMBLY 1/ August 2009 www.assemblymag.com
asb08094weiss.indd 7/6/09 3:09:13 PM
with an IOL. The hybrid devices are older pharmaceuticals into implantable
designed to treat the most common devices. Eye drops are the standard of
postoperative complications, such as care for most ophthalmic diseases, yet
inflammation, infection and secondary they have poor penetration into the eye
cataracts. and are inconvenient for patients to
“Drug therapy ease of use is of administer, often with four to six times
considerable importance as the world’s per day dosing.”
population continues to age,” says Tracy Klein’s company is developing front-
Klein, CEO of Inson Medical Systems of-the-eye drug delivery beads that are
Inc. (Bellevue, WA). “There is a smaller than a grain of rice. “We plan to
considerable opportunity to reformulate utilize this expertise on future products
INTRODUCING THE Sentinel C-28

Leak Test Instrument
The Sentinel C-28 is Cincinnati Test System’s latest

addition to the technologically advanced Sentinel leak
test instrument family. The C-28 uses the same proprietary
test algorithms processed on an advanced 32-bit system as the Sentinel n l
nel
I-24 multi-test type instrument, giving it the same fast and repeatable
results in a more compact package.
cka
kage.
age
a e
This instrument is used for cataract surgery. It
features a high-definition touchscreen display
and Bluetooth wireless technology. Improved TEST TYPES
fluidics enhance cutting efficiency, speed and Pressure or Vacuum Decay
accuracy when making smaller, noninvasive Pressure or Vacuum Drop
incisions. Photo courtesy Bausch & Lomb Inc. Pressure Rate of Change
Occlusion (Blockage)
The latest trend in IOLs is
toward corrective, foldable lenses FEATURES
that are structurally designed to Advanced Auto Set-up
minimize secondary cataracts from Auto Calibration
occurring. Most companies developing Vivid Full Color Display
Multi Language Selection
intraocular implants are focusing their
RS232 & Ethernet Communication
atio
tion
o
efforts on devices that treat back-of-
the-eye diseases, such as glaucoma and
The latest addition to the Sentinel
ntinel
nt nel family of leak test
e t instruments
ins r men s
acute macular degeneration.
For instance, Alcon recently
unveiled the third generation of its
Restor lens. The multi-focal device
contains 12 concentric “steps” around
the optic zone of the lens, which appear
as rings. They create different focusing
AT
TASI Group
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up
levels from near to distant vision. The Companyy
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Co
surgical procedure is painless and
only takes about 20 minutes. Some
ophthalmologists are recommending 513.367.6699
6699
the procedure as an alternative to the
more controversial Lasik treatment. providin g w or l d- c l as s l e a k t e s t an d
In addition, engineers and doctors as s em bl y v e r i f i c at i on s ol u t i on s
are currently developing polymeric
drug delivery devices that are implanted sal es@cincinnati-test.com cincinnati-test.com
at the time of cataract surgery along
Capital Spending Medical Device Assembly
Ophthalmic devices, such as intraocular lenses, are typically assembled in clean rooms.
Photo courtesy Carl Zeiss Meditec AG
for back-of-the-eye applications,” he “Recently, there have been some

explains. “We are also in very early drug treatments approved for wet-form
COLOR-CODED development discussions with potential AMD, but this typically consists of an
CONNECTORS partners who are interested in utilizing injection into the eye every couple of
SIMPLIFY FIELD our technology to create IOLs capable
of drug delivery.”
months,” Ashton points out. “A [more]
effective and less invasive treatment
INSTALLATION. Implantable intraocular lenses pose for this disease [would] be quite an
numerous manufacturing challenges. advantage.”
Forget paging through
“The main challenge for us is to make a Ashton and his colleagues
pinout diagrams at every
installation. TURCK has
device small enough to be inserted with have recently developed a variety
added color-coded and the lens, yet big enough to hold enough of ophthalmic devices for either
clearly labeled pinouts to drug,” says Klein. “There are also implantation or injection into the eye.
the company's wide variety technical challenges to overcome with The devices are made from a proprietary
of connectors, so installation existing injection molding techniques porous silicon material.
is faster and easier. when making devices this small.” Vitrasert was the first sustained
For instance, lenses must be extreme- release device approved for back-of-
Connectors are available for: ly thin to be flexible and comfortable to the-eye applications. It’s about the size
t%FWJDF/FU™ patients. Klein believes the ophthalmic of a pepper corn (6 millimeters long
t'06/%"5*0/mFMECVT™
device industry may be able to adapt and 2.5 millimeters wide). The device is
existing semiconductor manufacturing surgically implanted into the eye, where
®
t130'*#64 %1 technology and equipment if devices it releases drugs for six to eight months.
® get smaller. “Because the drug is released directly
t"4*OUFSGBDF
“[However], ophthalmic implantable into the eye, it requires approximately
t4UBOEBSE.DPOOFDUPSTBSF devices must be as long-acting as 20,000 times less drug than would be
BMTPBWBJMBCMF possible for obvious reasons,” says needed if given intravenously,” says
Klein. “Therefore, they are unlikely to Ashton.
get much smaller. In addition, surgeons Retisert is a smaller device that is
generally want devices they can retrieve 5.25 millimeters long and 1.5 millime-
if necessary.” ters wide, or about the size of a grain of
Call us with your next application: “The goal at the moment is to achieve rice. It lasts 2.5 years after implantation
1-800-544-7769 better efficacy with less invasive proce- into the eye. “As it releases its drug
email: turckusa@turck.com dures,” notes Paul Ashton, M.D., presi- directly into the eye, it delivers about
www.turck.com dent of pSivida Corp. (Watertown, MA). 200,000 times less drug than would
“There are a lot of blinding diseases be needed if the patient took the drug
for which there are no drug treatments orally,” claims Ashton. It is the only
yet approved. These diseases include FDA-approved treatment for posterior
© 2009 TURCK, Inc. dry age-related macular degeneration uveitis, a potentially blinding disease.
(AMD) and diabetic retinopathy. “Implanting either Vitrasert or Retisert
is a little like having a cataract opera- Your Global Distributor of Adhesives,
tion,” says Ashton. Sealants and Assembly Equipment
The next step in the evolution of this
series of implantable devices is called Electronic Assembly
Iluvien. The device is much smaller
& Protection
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and 0.5 millimeter wide), but it’s Thermal Management
designed to last about the same length Solutions
of time. “It’s about the length of an
eyelash and is small enough to fit into UV Curing Systems
a needle,” says Ashton. “This allows it & Accessories
to be injected directly into the eye in Dispensing Equipment
an office visit [as opposed to outpatient
& Surface Preparation
surgery, with fewer complications]. The
procedure is also far cheaper.”
According to Ashton, future
ophthalmic devices will continue to
get smaller and more sophisticated. ellsworth.com/Assembly.html
“Bioerodible systems are already in early
stages of testing,” he points out. “Applying
existing semiconductor [manufacturing
processes] and nanotechnology [will
create] ‘intelligent’ devices that respond ISO 9001:2000
to a disease or tell a physician if they are
about to run out [of a drug].” Visit our website and chat with the Glue DoctorTM about an adhesive assembly solution.
In addition to improved lens implants www.ellsworth.com 877-262-6029
and drug-device hybrids, another new
device that intrigues many ophthal-
mologists is the artificial retina. “This
device has given hope to patients asb08094ells.indd
have lost vision from disabling retinal
who
Technifor Direct Part Marking
1 7/14/09 1:14:28 PM
diseases such as macular degeneration,”

says Shatz. “While the resolution is and Traceability
currently only able to allow for ambula-
tory vision, higher resolution electrode
arrays under development will be able
to differentiate letters and objects.”
The artificial retina, called Argus II,
is being developed by engineers at Oak
Ridge National Laboratory (Oak Ridge,
TN) and the University of Southern Micro-Percussion Scribing Laser Marking
California (Los Angeles). It consists
of an array of 60 electrodes that are
attached to the retina. The electrodes Contact us for in-plant
conduct information acquired from an analysis and demos.
external camera to the retina to pro-
vide a rudimentary form of sight. The
device has already been implanted in
six patients. A newer, higher resolution Tag Marking 2D Coding
model will be available within the next & Reading
few years. A 800-394-9101
Technifor, Inc.
For reprints of this article, Tel. 704-525-5230
Fax. 704-525-5240
www.technifor.com
please contact Cindy Williams
at williamsc@bnpmedia.com e-mail: tfinc@usa.technifor.com UID Compliant
or 610-436-4220 ext. 8516.
ASSEMBLY Parts Marking
When All You

Need Is a Dot
Marking parts with colored
M
anufacturers mark parts has been completed. This is especially
for many reasons: to useful if that process does not visibly
inks or stains is a fast, easy differentiate between
similar-looking parts; to
change the parts.
Marking systems are often integrated
way to differentiate between indicate that a process into testing or production fixtures. An
has been performed or example is a flywheel that gets mounted
similar-looking components, a quality check has been passed; to on an engine with multiple bolts, which
facilitate assembly; or to link a product are then simultaneously tightened.
indicate pass-fail status or component to the assembly line or When all of the bolts have been torqued
machine on which it was produced. to specification, the marking device
or confirm that a specific Parts like calibration screws may even moves into position and applies a dot
process has been performed. be marked with stains that only become
visible under ultraviolet light to indicate
to confirm that the operation was per-
formed correctly. If the dot is not there,
whether they have operators downstream will immediately
been tampered with. know that additional inspection or cor-
One of the most rective action is required.
common uses of color
marking is to make Clogging can be
it easier to tell the
difference between minimized by using
parts that look similar.
Although such parts a low-volume, low-
may be marked
with numbers, pressure spray
letters or some other
i d e n t i fi e r, s o m e
system.
companies choose Parts are also frequently marked with
to color-code them color to facilitate assembly processes.
as well, to speed and For example, assemblers may put a dot
Parts such as calibration screws can be marked simplify identification on the shop of stain on brake calipers to confirm
with stains that only become visible under floor. For example, two springs may that pads have been installed before
ultraviolet light to indicate whether they have appear identical, but may function very mounting rims and tires. Or, a shaft
been tampered with. Photo courtesy ITW DYKEM
differently. Marking each one with a could be marked to indicate which end
different color stripe is a simple way to to insert.
By John Keating tell them apart. Marking is also used in automotive
Business Unit Manager, ITW DYKEM Another major use for parts marking and other stamping processes to check
Olathe, KS systems is in quality control. Parts the contours of stamped parts during
and are often marked after a test has been setup to indicate whether a bend has
Claude Bergeron performed to indicate whether they have the correct radius or a crease is straight.
Product Line Manager, EFD Inc. passed or failed. Parts are also marked In applications like this, color marking
East Providence, RI to indicate that a particular process provides an easy way to point out any
discrepancies so the operator marking applications involving
can fine-tune the press setup. tight tolerances, such as engine
rods. Transparent stains will not
Three Marking Methods settle or separate.
Common part marking Opaque stains use more
methods include handheld pigment to produce a heavier
valve-actuated markers, contact mark, and perform well on both
marking systems that press light and dark substrates. These
a stain-saturated pad against stains apply slightly thicker
the part, and noncontact spray than transparent stains and take
marking systems. slightly longer to dry. Thickness
The simplest of all marking can be adjusted by adding
“systems” are handheld valve- thinner.
actuated markers, which are Because they contain more
often used in processes such as pigment, opaque stains will
filling an automatic transmission settle over time, and daubers will
with fluid and then marking the need to be periodically agitated
dipstick for visual confirmation. to work properly. Opaque stains
Contact marking systems also increase the likelihood of
consist of an ink or stain reser- spray nozzles clogging and
voir fitted with a pad or dauber requiring maintenance.
and mounted on an air cylinder Nozzle clogging is a common
or similar device. As the part problem with spray valves,
moves into position or the test particularly when using heavily
or process is completed, the pigmented, opaque paints and
actuator advances to press the stains. To avoid applying a This spray valve has a dual-ported fluid head. A programmable air
delay after each shot keeps the nozzle clean and reduces clogging
saturated dauber against the part. thick, heavy spray mark that and maintenance. Photo courtesy EFD Inc.
Depending on the marking fluid, is slow to dry, valve stroke is
the parts may need to be clean usually shortened to “choke
and dry to achieve an acceptable down” the aperture to reduce
mark. coating thickness. This causes
Noncontact marking systems the pigment to be filtered out of
typically use a pneumatic spray suspension at the valve nozzle,
valve to apply spots, stripes and causing it to clog.
bands, with stain supplied from Clogging can be minimized
a tank or disposable reservoir. by using a low-volume, low-
Depending on the application, pressure (LVLP) spray system
the valve can be mounted in a to apply the stain. Because
fixed location or attached to an LVLP designs work with lower
actuator that moves it to the part. pressures and flow rates than
In some processes, the part is standard spray systems, a longer
rotated while the valve applies valve stroke can be used. This
a band of color around the outer leaves more space around the
circumference. valve needle, which reduces the
possibility of pigment building
Pigment and Maintenance up to the point where it eventually
Marking fluids are commonly blocks the valve nozzle.
referred to as inks, staining colors Separation is another issue
or paints, and generally fall with many pigmented stains.
into one of two classifications: This occurs when the pigment
transparent or opaque. separates from the carrier and
Transparent staining colors settles to the bottom of the
have a thinner viscosity than reservoir, resulting in fainter, less
opaque stains and dry slightly consistent marks that may not be This spray marking system uses a motorized gear pump to keep
faster. They are typically used on picked up by visual scanning pigmented inks in suspension and constantly circulating through
lighter colored substrates or in systems. the valve. Illustration courtesy EFD Inc.

Parts Marking
spray marking system is an example of
this type of equipment. A motor-driven
gear pump pulls fluid from the reservoir
and supplies it to the spray valve, where
it enters one side of the fluid head and
exits the other. As fluid is returned to the
reservoir, it produces a slight agitation
that keeps the pigment from settling
at the bottom of the tank. Because
as little as 1 psi is sufficient pressure
to keep the marking fluid constantly
recirculating, a long valve stroke can be
used to maintain open space around the
valve needle, while a programmable air
delay after each shot keeps the nozzle
clean and further reduces the risk of
clogging.
Choosing a Marking System

When comparing contact and
A simple dot of color can differentiate between similar-looking parts; indicate that a quality check noncontact marking systems, engineers
has been passed; or link a product to the assembly line or machine on which it was produced. should consider these factors:
Photo courtesy ITW DYKEM 䡵 marking speed.
Both issues—clogging and a recirculating pump that keeps the 䡵 the cost of the marking fluid and
separation—can be prevented with marking fluid moving so the pigment need to maintain inventory (individual
an LVLP spray marking system remains in suspension. stain bottles and applicators vs. less
with a double-ported fluid head and EFD’s new 781RC recirculating expensive bulk bottles).
䡵 the need to regularly monitor the
system to ensure ink is in the bottle vs.
using a tank that can be filled once at
the start of a shift.
䡵 time needed to change ink bottles or
refill a tank and whether the line must
be shut down to do this.
䡵 time and cost of replacing
contaminated or dried out pads and
daubers.
Once maintenance requirements,
Ergonomic Workplaces and Assembly Lines downtime, fluid costs and line speeds
have been considered, a noncontact spray
Conductix-Wampfler has one critical mission: marking system often proves to be a more
To supply manufacturers with a wide range economical long-term choice. A
of safe, ergonomic overhead energy supply
and material handling solutions for assembly
Electric & Air Supply lines and work cells. Our custom systems For reprints of this article,
Systems include the right mix of tool transporters, please contact Cindy Williams
tool balancers, and overhead electric/air
supply systems to keep your assembly lines at williamsc@bnpmedia.com
running at peak efficiency. Our rugged, low or 610-436-4220 ext. 8516.
maintenance products are time-tested in
demanding environments and backed by a
Equipment Carriers worldwide sales and service network.
Contact us today with your system

ASSEMBLY ONLINE
requirements! For more information on parts marking,
Tool Transporters visit www.assemblymag.com to read these
Balancers articles:
䡲 On Your Mark.
Conductix-Wampfler | 8091 Production Drive | Florence, KY 41042 䡲 Rubber Stamping Assembly.
Tel: (800) 326 2899 | Fax: (859) 814 2110 info.us@conductix.com | www.conductix.com
䡲 The Expanded Reach of Laser Marking.
See us at ATExpo, Booths 727 & 1421
Assemble it faster, better, for less.
Find cost saving new products, technologies, and ideas at ATExpo.
EXHIBITION & CONFERENCE

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ASSEMBLY Electronics Assembly
Riding the
Mini Wave
Automated selective soldering
S
elective soldering with a along two additional axes of motion:
miniature wave or fountain tilt and rotation.
technology saves EMS of molten solder offers many
advantages compared with
These fourth and fifth axes enable
the solder wave to get around bottom-
facilities time and money. conventional wave soldering side components and penetrate areas
equipment. It requires less that otherwise could not be reached by
energy, generates less dross, provides a three-axis system. In addition, top-side
more control, and can reach certain gantry systems can tilt boards for angled
joints that would otherwise be soldering, which can improve yields.
inaccessible. Moreover, there’s no need
for custom-made pallets or shielding for Different Strokes: EMS Views
the boards. Change is a constant in electronics
These systems can be assembly. New alloys, fluxes and
equipped with a single temperature demands are the norm.
circular nozzle 2 to 20 Production volumes increase and
millimeters in diameter, decrease quickly, and design life
a rectangular nozzle
4 to 8 inches long, or “We have
multiple nozzles for
soldering more than one decreased the cost
joint simultaneously.
Molten solder is pumped of labor by at least
through the nozzle to
create a fountain with a half.”—Todd King,
directional or spherical
shape.
E.I. Microcircuits
In some systems, the cycles can be short. Floor space is at a
printed circuit board is premium, and there is a constant push to
held stationary, and reduce costs, increase productivity and
Molten solder is pumped through this small the solder fountain moves beneath it improve quality. In this environment,
nozzle to create a fountain with a directional or to solder pins, rows and connectors. assemblers must run lean, green and
spherical shape. The fountain travels in three axes (X, mean. This has opened up opportunities
Y and Z) up to solder points and down for selective soldering technology.
and around bottom-side components. Dave Sackett is a consulting
Precise motion control and the small engineer in Maplewood, MN, who
size of the wave prevent damage to has worked with many electronics
By Reed Gaither nearby components and pads. assemblers. He recommends selective
CEO Other systems hold the fountain soldering systems driven by precision
RPS Automation LLC stationary and move the PCB. Often servomotors, as opposed to inexpensive
Spokane Valley, WA referred to as “top-side gantry” systems, stepper motors. Automatic loading is
rgaither@rpsautomation.com these machines can position boards also a good feature.
“Handling of PCBs should be masking or large copper ground
tool-free when possible,” he says. planes, which are difficult to solder
“Some systems use expensive manually. Selective soldering with
and time-consuming tooling for a mini wave provides constant heat
different sizes of PCBs. [This] can like traditional wave soldering
substantially reduce the usefulness equipment, but with less waste.
of the system as an economical and “We expect volumes to increase
high-mix production tool.” in these applications,” King says.
Programmability is particularly “[These boards] will go directly
important for any machine in a to selective soldering, bypassing
high-mix assembly environment. wave or hand soldering entirely.”
“Software should provide a simple In the past, E.I. Microcircuits
user interface and utilize scanned would sometimes run mixed-
images or Gerber data,” Sackett technology assemblies through a
says. “It should only take minutes wave soldering machine and then
to select solder points and nozzle another soldering operation for
configurations. A simple jog-to- difficult through-hole components.
teach set-up camera could also be Now, these assemblies go directly
used to program a board,” he says. to the selective soldering system.
For high-mix production, the “It can get in-between deep, tight
system should be able to store parts and navigate around large
an unlimited array of soldering components with consistent
programs. To save time and prevent repeatability,” says King. “You
errors, programs can be triggered simply can’t get that manually,
automatically through a bar code regardless of how adept the operators
reader. might be. ...We have decreased the
Soldering nozzles come in various shapes and sizes to suit
cost of labor by at least half [using specific applications.
Filling a Gap selective soldering],” he says.
In the past, high-mix, low-
volume assemblers had two choices Replacing Wave
for assembling mixed-technology When Ayrshire Electronics
boards: wave soldering or manual first began looking at selective
soldering. “Our first choice was soldering technology, it had some
always wave soldering,” recalls concerns. James Beard, director
Todd King, vice president of of manufacturing for Ayrshire’s
operations at E.I. Microcircuits Inc. Oakdale, MN, facility, says the
in Mankato, MN. “It is the highest first machines he looked at were
volume and the most economical. not flexible or easy to program.
What prevents wave soldering “Everything was customized,” he
are unique components and some recalls. “You designed the board, and
tight configurations particularly then you had the selective soldering
in [radio frequency applications], [machine] designed around it. If you
or large components that cannot needed fast changeover, too bad.
be waved or masked. Then we Plus, the footprint of the machines
[reverted] to hand soldering.” was almost the size of a standard
With production runs between wave machine.”
500 and 10,000 pieces, manual Being a high-mix assembler,
soldering is costly, not only in terms Ayrshire needed flexibility. The
of labor, but also in quality control. company finally invested in a mini-
Two years ago, the company wave system that can easily switch
invested in its first selective from one program to another.
soldering system. Today, it has “It’s not tied to one product line
three in-line machines running both or niche,” Beard says. “It can do
Programmability is particularly important for any machine in
lead-free and standard boards. point-to-point when needed, or a high-mix assembly environment. Soldering software should
E.I. Microcircuits assembles drag soldering and a mini wave for provide a simple user interface and use scanned images or
many boards that require significant some larger areas if needed. The Gerber data.

Electronics Assembly
joints at a slightly slower rate than a
traditional wave-soldering machine, it’s
more efficient in the long run when
maintenance, uptime, consumables and
defect rates are factored in.
“We specialize in low- to medium-
volume, high-mix, double-sided,
surface-mount boards with maybe one
or two through-hole parts on them,” says
Beard. “Instead of using a wave solder
[machine, which required] custom
pallets or a masking step, our assemblies
now go directly from the dispensing line
to the selective soldering step and then
on to various inspections.”
Eliminating the wave soldering
system saved Ayrshire approximately
$120 per day in energy costs and
eliminated some 3,500 pounds of dross.
“The dross from selective soldering is
In some selective soldering systems, the board is held stationary, and the solder fountain moves only spoonfuls,” Beard says.
beneath it. In others, the fountain remains stationary, and the board moves.
Ayrshire also saved on labor. “When
system is integrated in-line for complete With their smaller wave nozzles, we went to selective soldering two and a
automated assembly, and the best part is selective soldering systems are much half years ago, we had 16 people doing
that the footprint is 3.5 feet by 4 feet.” better suited for boards that are 4 inches hand soldering during the first shift,
After a short while, Ayrshire wide. The system can accommodate eight people on the second shift, and
completely eliminated wave soldering boards that are more than 4 inches wide four on the third,” Beard recalls. “Today,
on its assembly line. A standard wave by moving them in a serpentine pattern we are building the same volume and
soldering system produces a wave that over the wave. same mix of products, and we are down
is 18 to 24 inches wide, whereas most Soldering programs can be adjusted to six people on the day shift. That’s a
PCBs are much smaller. This means the to optimize key parameters, such as manpower reduction of 75 percent.”
machine is heating a lot of solder and speed, immersion depth, dwell time Selective soldering has made
producing a lot of dross unnecessarily, and temperature. The net result is that a difference in defect rates, too,
explains Beard. while the smaller wave nozzle solders particularly with small boards for radio
frequency applications. “[If there’s] a
tiny icicle on a joint, all of a sudden
you have an antenna and it throws off
the whole board,” Beard says. “That’s
where selective soldering really shines.
It has cut our defects—bridging, damage
to other parts, and so forth—down to
virtually zero.” A
For reprints of this article,

please contact Cindy Williams
at williamsc@bnpmedia.com
or 610-436-4220 ext. 8516.
ASSEMBLY ONLINE
For more information on soldering technology,
visit www.assemblymag.com to read these
articles:
Although the small nozzle solders joints at a slightly slower rate than a traditional wave-
Three Boards in a Fountain.
soldering machine, it’s more efficient in the long run when maintenance, consumables and defect Soldering Soldiers.
rates are factored in. Step up to the Bar.
ASSEMBLY ASSEMBLY EVENTS
Don’t Miss
the Big Show
Find the tools your company
D
espite the economic hard times, Technology Expo (ATExpo), set for
assemblers in the United States Sept. 22-24 at the Donald E. Stephens
needs to succeed at ATExpo will still spend more than
$2.5 billion on new assembly
Convention Center in Rosemont, IL,
immediately adjacent to Chicago’s
2009. equipment this year, according O’Hare airport.
to ASSEMBLY magazine’s As in 2008, ATExpo 2009, which is
13th annual capital equipment spending sponsored by ASSEMBLY magazine,
report. will be co-located with the Medical
Not only that, as the economy works Design & Manufacturing Midwest
its way out of the downturn, assemblers (MD&M Midwest) show and the Green
are going to have to work smarter and Manufacturing Expo. Also co-located
with this year’s ATExpo will be
Quality Expo and the new Design &
Manufacturing Midwest and Electronics
Midwest shows.
In addition, ATExpo 2009 will
feature a range of conference sessions,
including a quality track, a design track,
a medical track, a green manufacturing
track, and a track on automation and
assembly.
The latter, which is being sponsored
and organized by ASSEMBLY
magazine, will be comprised of a number
of specialized sessions, including
those on plastics assembly, affordable
automation, lean manufacturing,
compliant design, affordable robotics for
smaller manufacturers, machine vision
and recycling. (See sidebar, page 38.)
Building the Future

As it has been for more than a
quarter century, ATExpo is the one-
As the economy makes its way out of the more efficiently than ever if they are to stop source for assembly-related
downturn, assemblers will need to work succeed in an increasingly competitive equipment and materials, including
smarter and more efficiently than ever if they global economy. automated assembly systems, adhesive
are to succeed in an increasingly competitive To make sure your company has the and solder dispensing machines, robots,
global marketplace.
capital equipment it needs to survive conveyors, parts feeders, circuit board
By Adam Cort in this kind of environment, be sure assembly equipment, adhesives and
Senior Editor and check out this year’s Assembly sealants, mechanical fasteners, machine
ASSEMBLY EVENTS
Prepare for the Rebound

at the Assembly Conference
As the economy gets back on its feet again, assemblers are
going to have to work smarter and better than ever before to
remain competitive. This, in turn, will require not only the latest
technology, but new ways of thinking—both of which will be
the focus of this year’s assembly conference at ATExpo.
On Tuesday, Sept. 22, the conference kicks off with three
tracks: “The Ultimate Plastics Assembly Seminar,” “Lean
Manufacturing,” and “How to Profit from Automated
Assembly.”
The plastics assembly track will feature industry experts
addressing everything from ultrasonic welding and light-cure
adhesives, to the best ways of placing inserts and using the latest
environmentally friendly materials.
The track on lean manufacturing will include speakers such
as Kevin Duggan, founder of The Institute for Operational
Excellence, discussing how to employ lean techniques to grow principal and expert on supply chain management at Archstone
a business in a recovering economy. The automation track will Consulting, will give a pair of presentations titled “North
feature speakers such as Mikron Corp.’s Jim Mueller, who will America: the New Low Cost Manufacturer” and “Planning
explain how designing a new product with assembly in mind for the Rebound.” In these sessions, attendees will learn how
can reduce costs. companies can position themselves to take advantage of the
On Wednesday, the conference continues with three more latest trends in manufacturing.
tracks: “Technology for Profitable Assembly,” “Robots and Finally, the conference will end on Thursday with a pair
Vision,” and “Preparing for the Economic Recovery.” of workshops: “Reducing Part Counts and Product Costs
The session on profitable assembly will begin with Through Compliant Design” and “Lean Workshop:
presentations on resistance welding, crimp quality verification, Operating System Design.”
and press fits and process monitoring. In the afternoon, the track Chairing the session on complaint design will be Sridhar Kota,
continues with a panel discussion on how even small companies Ph.D., a professor of mechanical engineering at the University
can benefit from robotics. There will also be a presentation of Michigan. Leading the workshop on lean manufacturing will
by Denise Coogan, manager for safety and environmental be Matt Zayko of the Lean Transformations Group.
compliance at Subaru of Indiana Automotive Inc., on how her Individual sessions are about an hour long, and will begin
plant has cut the amount of solid waste it generates to zero. at 9 a.m. and end at 3 p.m. on Tuesday and Wednesday.
The track on robots and vision will include sessions on robots Thursday workshops will begin at 9 a.m. and finish at noon.
and the “green” economy, collaborative robots working in close For more information, including session abstracts and a
proximity to people, and how to employ machine vision to complete conference schedule, go to www.devicelink.com/
improve your bottom line. In the afternoon, Dr. John Kamauff, a expo/atexpo09/conference.html.
vision systems, power tools, presses, by-step demonstration on how to build systems, plant engineering products,
workstations, process monitoring an actual lean production area. motors, drives and other manufacturing
systems, and test and inspection Canon Communications is also support equipment.
equipment. creating an Innovation Briefs Theater, Similarly, Electronics Midwest will
The show also plays host to dozens a 50-seat amphitheater complete with be your one-stop source for the latest
of integrators and machine builders with its own screen, where experts can give in component insertion and placement
experience in assembling everything 30- to 40-minute seminars on various equipment, soldering machines
from the tiniest consumer gadgets to technologies. and everything else you’ll need to
high-end medical devices and mission- manufacture and package printed circuit
critical components for the automotive Co-Located Shows boards.
and aerospace industries. For those with responsibilities in the For those either already a part of, or
This year’s ATExpo will include areas of design and planning, this year’s planning to become a part of the red-
a number of what show organizer Design & Manufacturing Midwest show hot medical-device industry, MD&M
Canon Communications describes as will include exhibitors featuring the Midwest will bring together many of
technology-specific areas, including a latest in CAD, CAM and CAE software, the major equipment, materials and
sensors and vision area, a wire harness computer hardware and peripherals, service providers doing business in the
processing area and a new lean “factory,” contract manufacturing services, linear Midwest and beyond.
which will feature lectures and a step- motion devices, material handling In fact, the five states comprising the
upper Midwest—Illinois, Wisconsin,
Michigan, Indiana and Ohio—are
Join Us at the Lean Factory!
already home to some 1,800 medical
OEM facilities producing about $20
billion worth of medical devices and
equipment every year. Thanks to the
United States’ rapidly aging population
and continuing advances in medical
technology, those numbers will only get
bigger in the coming years.
Finally, for those looking to either
become a part of the new green
economy or cut their costs through
environmentally friendly technologies,
there is the Green Manufacturing
Expo.
Now in its second year, this event
focuses on sustainable manufacturing Sponsored by the Lean Factory and infrastructure; and tools that can be
and covers economically sound and Group, comprised of Bosch Rexroth used to create a visual factory.
nonpolluting manufacturing processes Corp., Orgatex Americas LLC, Attendees will see presentations
that conserve energy and natural Leonardo Group Americas, and Omron on lean manufacturing; interact with
resources. STI, this year’s Lean Factory exhibit experts in the field; and take part in the
Products and services featured will will demonstrate the importance of a step-by-step creation of the perfect lean
include solar and wind power systems, data-driven approach to line design; production environment, culminating
recyclable and reusable packaging, the need to create an environment that in an actual build demonstration on an
energy management software, and supports lean with the right equipment optimum lean line.
consulting for energy management,
recycling and waste treatment.
Last but certainly not least, for those
in search of the quickest possible return
on investment for their trade show dollar,
this year’s show will include an hourly
“grab bag giveaway.” Every day of the
show, between 10:30 a.m. and 3:30
p.m., there will be a drawing each hour,
with prizes including MacBook Air
laptops, Best Buy gift cards, iPhones,
and iPod Nanos.
Registration Information
A single entry badge allows attendees
to visit all six shows. If you preregister
online or bring show material with
you on-site, admission to the shows is
free. Otherwise, you will be charged an
expo-only fee of $55 to register on-site.
Online registration is available even on
show days.
For more information, current
exhibitor lists and to register for free
show admission, visit any of the show
web sites: www.atexpo.com, www.
manufacturingweek.com, www.
qualityexpo.com, www.mdmmidwest.
com, www.greenmfgexpo.com and
www.electronicsassemblyshow.com. A
Products
Grippers Certified for
Painting Robot Is Compact, Flexible
Clean Room Use The Paint Mate 200iA intelligent mini paint
Grippers are now certified for use in Class 5
robot can be used to paint small parts and
offers a cost-effective alternative in applica-
tions that would otherwise require multiple
fixed paint guns. The system incorporates all
the features of the popular LR Mate 200iC,
including wrist load capacity, repeatability and
speed. The robot is extremely flexible and can
be mounted on the floor, on a tabletop, at an
angle or inverted.
FANUC Robotics America Inc.
www.fanucrobotics.com
800-477-6268
Crimper Accommodates Multiple Stations

The CrimpCenter 36 can accommodate up to six processing stations and is suitable for a use in
clean rooms according to ISO 14644. Among
a variety of applications employing cross sections from 24 to 12 AWG. Modern manufacturing
the grippers now certified are PGN-plus paral-
materials and a number of new proprietary technologies allow for a compact, economic design
lel grippers, the DPG-plus sealed parallel grip-
without compromising quality.
per, the PZN-plus centric gripper, the DPZ-
Proven state-of-the-art compo-
plus sealed centric gripper, the MPG miniature
nents provide outstanding output
parallel gripper, the MPZ miniature centric
rates, while synchronized Ethernet
gripper and the SRU rotary module.
powerlink ensures fast and con-
SCHUNK Inc.
tinuous communication between
www.schunk.com
software and servo drives.
800-772-4865
Schleuniger
www.schleuniger-na.com
603-668-8117
Reactor H-VR Offers
Adjustable Ratio Settings
The Reactor H-VR is a simple-to-operate, Test, Monitor System Easy to Configure
variable-ratio dispensing system that can be The sigPOD PSV is an out-of-the-box, user con-
figurable system that can be used to test or monitor
virtually any operation during manufacturing, includ-
ing press, torque, vibration, dispense and functional
test. An easy-to-use setup interface allows operators
to leverage an expansive library of processing and
analysis tools. The system can be used on up to eight
channels to allow for greater output without sacrific-
ing quality.
Sciemetric Instruments
www.sciemetric.com
866-900-7054
Leak Detector
Minimizes Operator Error
MS-60Dry helium mass spectrometer leak detec-
used to process polyurethane foams and polyu-
tors can be used to test the integrity of a wide variety
rea coatings. Designed for materials that have
of systems, containers and parts using helium as a
extreme differences in viscosity between their
tracer gas. The MS-60Dry is available with a stan-
A and B components, the system allows end
dard 16 cfm Dry foreline-roughing pump for faster
users to spray infinitely variable volumetric
cycle times and use in clean room applications. The
ratios ranging between 1:1 and 2.5:1. Maxi-
system’s software allows users to both locate and
mum fluid output varies depending on the
measure leaks with ease, at the same time minimiz-
ratio setting.
ing operator error and maximizing throughput.
Graco Inc.
VIC Leak Detection
www.graco.com
www.vicleakdetection.com
877-844-7226
631-737-0900
Belt Conveyors Are polyethylene. The fasteners are intended for
Sturdier, Easy to Service one-time use and provide a cost effective
TB belt conveyors feature sturdy aluminum means of creating a lightweight assembly.
covers to protect their chains and pinions. In One size pin fits all lengths of posts. Posts
are available in lengths from 1/2 inch to 1 1/4
inches.
Micro Plastics Inc.
www.microplastics.com
800-466-1467
lower assembly costs. The adhesive is bright System Handles

blue in its uncured state making it easy to Sensitive Materials
see on the surface of substrates, in deep wells The Dos A300 dispenser can be used to
or when sandwiched between two layers of process everything from liquid, self-leveling
material.
DYMAX Corp.
www.dymax.com
877-396-2963
addition to providing superior protection, the
covers make the conveyors easier to service Microscope Records
because they require fewer locking screws. High-Speed Motion
The conveyors are available in six different The VW-6000 motion analysis microscope is
frame widths, from 60 to 250 millimeters, and the world’s first microscope with high-speed
can be ordered with either a single or double magnified video-capture capabilities. The sys-
belt. The drive unit can be installed horizon- tem can record up to 24,000 frames per second,
tally or vertically at any point along the entire
length of the frame.
Montech
www.montech.com
Robot Has ‘Zero’ Footprint materials to abrasive resins. It is especially

The new overhead-mounted RS3 SCARA well suited to handling liquid and medium-
robot is literally a “zero footprint” robot, sav- viscosity polyurethanes, silicones and epoxies
ing assemblers valuable floor space. The sys- with or without filling materials. It can also be
tem can be easily integrated into a compact used for dispensing humidity-sensitive materi-
assembly cell and offers 450 degrees of axis als that need to be processed under vacuum.
rotation for omni directional access. It comes The system can be configured as a stand-alone
standard with the low-cost, high-performance manual workstation or as part of a larger pro-
duction line.
Scheugenpflug
www.scheugenpflug.de
making it possible to film moving targets that
cannot be otherwise captured. Because it is Mobile Workstation
small and portable, the system can be used on Safeguards Laptops
the factory floor as well as in the lab. This mobile laptop computer workstation pro-
Keyence Corp. of America vides a secure place to both store and use a
www.keyence.com/vw laptop, at the same time positioning it at a com-
Posts, Pins Facilitate

Light Assembly
New post-and-pin combination includes pins
molded in white polycarbonate material and
Micro PowerDrive RC180 controller to facili-
posts in various lengths molded in white
tate ease of use and reliability.
EPSON Robots
www.robots.epson.com
562-290-5910
Adhesive Turns from Blue to Clear

The 3-20794 See-Cure adhesive is a color-
changing material formulated with Ultra-Red
fluorescing technology. It bonds to a variety of fortable work height. The station’s four large-
plastics and cures clear in less than a second diameter swivel casters ensure easy rolling and
when exposed to high-intensity UV light, maneuverability. The casters can be locked for
enabling faster processing, greater output and greater safety and stability while working. The

Products
station provides a workspace that is 42 inches kit includes all necessary mounting hardware, Sensors Combine Accuracy, Value
wide, 26 inches deep and 38 inches high. Cus- making installation as simple as tightening The OD Value line of optical displacement
tom dimensions are also available. down the bolts. sensors provides high-accuracy performance
Creform Corp. GAM at a competitive price with a variety of inter-
www.creform.com www.gamweb.com face capabilities for use in a wide range of
800-839-8823 888-GAM-7117
Slides Available in Five Days Rails Provide Accuracy,

Customized LSK linear slide kits are now Cost Savings
available in just five days, dramatically cutting LFS 12 Series low-profile linear rails and car-
lead times and reducing the overall cost of
system assembly. The kits are compatible with
any linear slide, belt or ball screw actuator,
and any motor or gearbox. Standardized com-
ponents are available for those applications
requiring extra stiffness or dampening. Each
riages can be used in those applications that

require low cost and accuracy, such as door quality control applications in the automo-
enclosures and transfer systems. Each linear tive, robotics and electronics-semiconductor
rail and carriage set employs a set of mating industries. The sensors can measure targets
V-groove rollers. The standard rail length is 3 regardless of color or reflectivity and include
meters, but custom lengths are available. an easy-to-read bar graph display for fast
Techno Inc. installation and maintenance.
www.technoautomation.com SICK
800-819-3366 www.sickusa.com
268 METRIC HINGES

Leak, Mass Flow and
for a cleaner environment Electrical Testers
starting at $2990.00
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www.amsp.biz Fax: (734) 451-9462
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Website: www.ateq.com

Asb02084AMSP.indd 1 1/3/08 9:17:55 AM
Dispense, Spray System Pipette Enables three sizes and offers positive displacement
Includes Tilt Feature Contaminate-Free Dispensing dispensing in a range of volumes from 0.01 to
The Precisioncoat spray and dispense system The Stepper pipette enables contaminate-free 1.00 milliliter. Each pipette can dispense up to
now includes a programmable tilt and rotate dispensing in a simple-to-operate, handheld 100 shots per fill.
feature, needle calibration and a vision system system. The dispenser incorporates a light- Tridak
to help customers achieve maximum effi- weight, ergonomic design and is constructed www.tridak.com
ciency, flexibility and accuracy as they spray of aluminum for maximum durability. Users 860-626-6700
Readers Fill Multiple Niches

HS-1 and HS-2D handheld readers provide
out-of-box, plug-and-play performance and
and dispense coatings onto printed circuit

assemblies and other devices and substrates.
The programmable tilt and rotate feature, in can be plugged into a number of standard
particular, allows users the flexibility of five Microsoft Office programs, including Word
separate axes to coat alongside and underneath and Excel. The HS-1 is lower-cost reader for
a wide variety of components. use with linear barcodes, such as those found
Specialty Coating Systems can dispense a variety of low- to medium- on printed black-and-white labels. The HS-2D
www.scscoatings.com viscosity materials. The pipette is available in reader is a higher performance model that can
INDUSTRIAL
ROBOTS
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&
SR-SERIES small cartesian robots are suitable for Specializing in packaging adhesives and encapsulants in convenient
syringe and cartridge systems, ideal of Electronic assembly.
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precision up to ±0.02 (±0.005mm), and low noise. • Premixed and frozen two component
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TEL:1-201-944-0996 • FAX: 1-201-944-2999

ASB06094SAEJONG.indd 1 5/6/09 10:14:19 AM
Asb08094kit.indd 1
www.assemblymag.com August 2009 / ASSE M B7/9/09
LY 43 3:45:41 PM
Products
be used to decode both linear barcodes and insulation residue as it is removed from the in the automotive and commercial vehicle
2D symbols in a wide range of environments, wires during stripping. industries.
including clean rooms. Eraser Inc. Dürr Ecoclean
Microscan www.eraser.com www.durr-ecoclean.com
www.microscan.com 315-454-3237
TFT Systems Available
Wire Stripper Collects Robotic Cleaner with Hollow Shafts
Insulation Residue Handles Heavier Loads Torque Functional Test (TFT) systems pro-
The Model DV1 twin-wheel wire stripper with Ecoclean flexible robotic cleaners can now viding monitored and measured amounts of
integral dust collector can be used to strip accommodate industrial parts weighing up to torque during assembly and test operations are
magnet, enamel and film-insulated wires, as now available in a hollow shaft configuration.
well as round, rectangular and square section The new feature allows operators to access
wires with insulations such as Formvar, components with tools or sensors inserted
ML, Dayglass, Isonel and Polythermaleze. through the center hole at the same time the
The system’s integral dust collection traps
300 kilograms, thanks to a new conveyor com-

ponent that reorients the parts being cleaned
via a tilting station, thereby allowing the robot
to handle heavier parts than in the past. The
system is especially well suited to cleaning
parts with complex geometries, like those
ELECTR C! • Electric Sheet Metal

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asb08091phd.indd 1 ASB03081Visu.indd
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components are being processed. The TFTs employ servomotors, pre- resistant to motor oils,
cision position sensing feedback technology and extremely accurate transmission fluids
torque transducers to produce controlled torque inputs and feedback and most other work-
monitoring. related compounds,
Promess Inc. such as greases and
www.promessinc.com cutting fluids. The
810-229-9334 stains can be applied
by brushing, spraying
Tubing Good for Appliances, Food Industry or dipping. Dry time is
Ethelplas tubing is extruded from nontoxic, 100 percent virgin linear less than 15 minutes.
low-density Polyethylene resin for use in commercial and household ITW
appliances, the food industry and laboratory testing equipment. It www.dymon.com
provides good resistance to chemicals and is nonconductive. The tub- 800-443-9536
ing is available in nine
different sizes, ranging
from a 1/16-inch inner
diameter to a 5/8-inch
inner diameter.
Ark-Plas Products Inc.
www.ark-plas.com
870-453-2343
Laser Scanner Is Precise, Portable

The SLP-500 3D laser scanning probe is a high-precision probe deliver-
ing virtually noise-free scan data for use in the automotive and aerospace
industries. The system
provides a laser line
length of 50 millime-
ters and scans at very Applications include:
high speeds, making it small linear slides, medical
equipment, instrumentation, • High Energy Capacity in
ideal for use in scan-
packaging, material handling, Minimum Sized Packages
ning mid- to large-
sized objects, such rotary actuators and more • Proven Designs & Performance
as molds, stampings • Ideal for Mounting in
and sheet metal. The Confined Spaces
probes are portable and can be easily integrated with a coordinate mea- • Self-Compensating
suring machine (CMM) arm. & Adjustable Models
Main
Laser Design Inc. Catalog
www.laserdesign.com Available
Online
952-884-9648
Stains Are Environmentally Friendly Farmington Hills, MI 48335

tel: 800-521-3320 fax: 248-476-2470
DYKEM water-based stains can be used to permanently color code e-mail: shocks@acecontrols.com
springs, small parts, tools and finished assemblies. The stains produce acecontrols.com
little odor and emit few VOC’s. Their non-xylene based formulation is
asb08094ace.indd 1 6/25/09 1:13:33 PM

asb05094janome.indd 1 4/6/09 2:28:57 PM
Products
Clamps Combine wafer without leaving a mark, even when han-

Accuracy, Ease of Use dling wafers that are smaller than the contact
Zero Point clamps offer ease of alignment, surface of the gripper. The gripper can also be
high-accuracy positioning and high clamping safely used in a clean room environment.
forces. They can be used with either hydraulic Schmalz Inc.
www.vacuworld.comasb0809
Gantries Provide Speed, Precision

height, 5-inch-diameter casters and a choice of AGS15000 series Cartesian gantries incorpo-
hanging drawers are also available. The benches rate a planar design that minimizes dynamic
come in light gray, bright blue or sand. pitch errors for use in a wide range of precision
Lista International Corp. applications, including stencil cutting, fuel
or pneumatic actuation. Each clamp employs a
www.listaintl.com
series of balls that roll freely in a form-fitting
800-722-3020
ball channel that allows them to easily reposi-
tion themselves, allowing heavy fixtures to
self-align easily. All components are made of Gripper Configured for
stainless steel. Solar Production
Jergens Inc. The new SWG vacuum gripper is configured
www.jergensinc.com for precise, gentle handling of highly sensitive
800-537-4367 wafers and solar cells. It provides a cycle time
of 1 second and grips the entire surface of the
Workbenches Are cell manufacture, high-speed pick-and-place
systems, automated assembly, dispensing and
Sturdy, Economical high-accuracy inspection. The system’s BLM
The Arlink 7000 workbench is a cost-effective,
and BLMH series brushless linear servomo-
easily assembled, general-purpose workbench
tors provide speeds of up to 3 mps and 5G
capable of supporting up to 1,000 pounds. It is
acceleration.
available with a range of work surfaces, includ- Aerotech
ing plastic laminate, static dissipative laminate www.aerotech.com
and butcher block. Leg extenders for extra 412-963-7470
Classified
Need Work Benches
?
www.1proline.com
847-534-1000
LEAN CELL SPECIALISTS
⽧ CUSTOM ASSEMBLY EQUIPMENT
In Stock ⽧ QUALITY CONTROL SYSTEMS
⽧ SPECIAL MACHINERY
⽧ SPECIAL FIXTURES
⽧ PRECISION CNC MACHINING
www.krygierdesign.com
www.assemblymag.com
For information on Classified

Advertising call Vito Laudati:
630-694-4018
Advertisers Index
Ace Controls ....................................................... 45 Promess ............................................................. IFC
AMSP All Metric Small Parts .......................... 42 Quality Bearings & Components .................... 12
Assembly Technology Expo 2009.................. 33 Robotic Industries Association ....................... 11
ATEQ .................................................................... 42 Saejong Industries ............................................. 43
Cincinnati Test Systems ................................... 27 Sankyo .................................................................. 24
Conductix-Wampfler.......................................... 32 Schleuniger Inc. .................................................. 10
DEPRAG Inc. ....................................................IBC Schmidt Technology .............................................5
Dymax ................................................................... 25 Schunk Inc. .............................................................3
Edgewater Automation ..................................... 13 Sciemetric ...............................................................7
EFD ..........................................................................1 Sealant Equipment & Engineering ................. 39
Ellsworth Adhesives ...................................29, 43 Technifor ............................................................... 29
I & J Fisnar Inc. ...................................................BC Techno .................................................................. 21
Janome Industrial Equipment USA Inc.......... 45 Techno Sommer ................................................. 12
Lista International Corp. ................................... 15 Turck ...................................................................... 28
PHD Inc................................................................ 44 Visumatic Industrial Products Inc. .................. 44
ProLine ....................................................................4 Weiss North America ........................................ 26
This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.
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Leading
Lean
Jamie Flinchbaugh
Partner
The Lean Learning Center
Novi, MI
Close the Knowledge Gap
I
n the past two columns, I understand. The assumption is that fifth time you ask “why.” The
have used the A3 improve- there is something you don’t quite intent is not documentation or
ment process to explore some understand, so focus on exactly ensuring a particular rigor. It is
of the subtler but broad skill what that might be. This requires a knowledge discovery process.
sets and mindsets of lean. A3 humility and curiosity. You must That, I believe, is it’s real
can be a helpful method to be willing to use what I consider value. Developing and testing a
guide your thinking, and it enables one of the more powerful phrases hypothesis is also a good way to
greater collaboration and coach- a leader can use, “I don’t know.” generate knowledge.
ing. Last month, I focused on the And you must have the curiosity to Why bother? The fact is,
imperative of good problem state- invest time and energy in pursuit you must close your knowledge
ments and the thinking that goes of that knowledge. gaps before you can close your
into them. This month, I move performance gaps. Closing
to the next quadrant of the performance gaps where the
A3, defining and clarifying knowledge is already clear
the current condition.
This section of an A3
Close knowledge gaps before and available is often simply
a matter of execution. If you
can be populated with data, closing performance gaps. only need to execute what
you already know, then the
stories, pictures and anything
else that helps explain the A3 won’t help you. The
current condition. It should thinking process enables you
explain why you are getting the The second fundamental to close performance gaps that
results that you are getting and question is, by what method can are more challenging. To close
where you must focus to make I learn this knowledge? There those gaps, new knowledge,
the required changes. But there is are many methods you may insight and maybe even wisdom
more to this section than simply deploy. I have written more than are required. If you try to close
cutting and pasting your favorite once about the power of direct the performance gap before
Excel chart. The underlying observation. Whenever you have you close the knowledge gap,
function of this quadrant is to to suspend your assumptions and you will ultimately end up back
drive learning and knowledge. trim your filters, you are more where you started.
Lean businesses constantly focus open to what is really going on. The second quadrant of the A3
on generating new knowledge Going directly to the point of is meant to capture the current
about how their processes and activity, whatever and wherever condition. The ability to do this is
organizations really work. In that is, can greatly expand your found in those two key questions.
this part of the A3 process, you knowledge. What do I need to learn more
should focus on that purpose. There are other methods. about? And, how can I learn it?
There are two fundamental You should deploy the simplest Keep these two questions in mind,
questions that help in this process. approach to gain the knowledge and you will move forward with a
The first is, what do I need to learn you need. The “5 Why” high probability of success.
more about? Another way to phrase problem-solving method is a
it would be, what specifically do I good example. In the “5 Why”
not understand in the areas where method, you keep asking “why” Email Jamie with comments via
I need to gain knowledge? There’s about a condition until you get jamie@leanlearningcenter.com.
no need to gather “new” knowledge to the root cause. Invariably, For his recommended books
about something you already you’ll hit the root cause by the see tinyurl.com/leadinglean

SCREWDRIVING AUTOMATION AIR MOTORS POWER TOOLS
TECHNOLOGY
V E R S A T I L E M I N I M A T® - E
INLINE HIGH TORQUE

—— Up to 160 inch lbs torque capacity
—— Torque-Holding-Time which
compensates for relaxing joints SFM with a
—— Push to Start Minimat®-E mounted
—— Ergonomic Design to a rotary index table
—— Non Slip Housing
[
HANDHELD
MINIMAT ®- E Angle-Head STATIONARY
[
Now available with up to
221 in. lbs. torque MINIMAT ®- E
MINIMAT ®- E Servo Angle-Head 159 in.lbs. torque
531 in.lbs. torque MINIMAT ®- E Servo
2,400 in.lbs. torque
PISTOLGRIP
—— All the functions of the
original inline Minimat®-E
—— Light Weight - starting
at 1.28 lbs
—— Ergonomic Design
—— Trigger Start
—— Non Slip Housing
DEPRAG, INC.
640 Hembry Street
Lewisville, Texas 75057-4726
972 221 8731 main
972 221 8163 fax
Catalog request:
catalog@depragusa.com
General e-mail:
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August 2009 www.assemblymag.com

ATExpo, Booth 705

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Choosing a Marking System

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EXHIBITION & CONFERENCE

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