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Manufacturers of all sizes see an uptick in productivity after adding a factory within a factory via an automated machining cell. The cells are small-scale, clearly defined production units, often for a family of similar parts or a product, and they typically include a robotic arm and one or more machine tools. These can include horizontal and vertical lathes, machining centers and grinders. The cell may also include a conveyor component.

For decades, plant personnel have performed insulation resistance tests with handheld megohmmeters to prevent motor failures that lead to costly unplanned shutdowns, failure-to-produce penalties and rewinding repairs. However, these tests only provide a “snapshot” of motor health. In a matter of days, motor windings and cables exposed to moisture, chemicals, contaminants or vibration can be compromised and fail at startup.

McDermott International is using Digital Twins to grow its business and to keep information flowing instead of trapped in silos.

More and more manufacturers are seeing productivity as a crucial factor to their business success. In the meantime, business models are changing from the large quantities and few variants to small quantities with frequently changed variants. This change requires high flexibility during production.

The automation debate is a captivating one, but for some it conjures up images of a world where their roles become obsolete, superseded by the ruthless efficiency and unwavering energy of machines.

One of the foundational aspects of Industry 4.0 protocols is the creation of electronic “digital twin” models of product data and production processes. This includes an exact replica of all machine tools, including complex work envelopes showing the particular spindles, fixtures, and cutting tools.

These days mirror the late 1990s, when the Internet evolved to widespread use—and the topic bedeviled many. But others—in banking and entertainment, for example—who quickly learned the new lingo and jumped at the chance to explore the Web’s potential benefited greatly. Today’s tantalizing topic: blockchain.

Well into the 21st century, the medical industry faces a host of intriguing challenges, from aging populations to a growing range of personalized and at-home diagnostic and care devices—all set against a backdrop of increasing digital collection, transfer and storage of sensitive patient data.

There’s nothing mysterious about the need for calibration. As Michael Wilm, business manager for calibration products, Renishaw Inc., West Dundee, Illinois, put it: “When you get gas for your car, you count on the pump being calibrated. That’s why we calibrate machine tools. If you don’t calibrate a machine tool you have no idea it’s going to give you reliable service for manufacturing your product.”

Maybe your company specializes in aerospace or medical components, and you need to produce complex geometries in metals too tough to cut via conventional machining methods.