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Unplanned downtime and production loss due to equipment failure is one of the leading losses for manufacturers. Most shops perform maintenance on a fixed schedule or on failure. This means a machine will be maintained regardless of how often it is used and unexpected breakdowns will stop production.

Simulation tools are making it much easier for manufacturers to optimize their processes, visualizing the entire path of production from NC metalcutting simulations through 3D design and factory-floor imaging.

Data management and the maintenance of clean, usable data for asset performance metrics pose great challenges for manufacturers today.

Consumer expectations have shifted to almost unrecognizable levels, catalyzed by innovative tech companies like Amazon, Lyft and Netflix. Previously acceptable levels of customer service are no longer good enough. Customers now expect real-time support and answers to complex questions at the ready, at a minimum.

Additive manufacturing is both growing and coping with growing pains. Companies “have to find ways to streamline” polishing and other finishing processes of 3D printed parts, industry consultant Terry Wohlers said today during a speech at RAPID + TCT.

The integration of additive and subtractive enables product designers to pursue product enhancements that could not be manufactured in any other process. At the same time, this combination is reducing the time it takes to prepare for parts production, including acquiring the necessary tooling.

Companies strategically adopt cutting-edge solutions to help solidify their position within a competitive marketplace. Years ago, blue light 3D scanning technology was implemented to help product development and alleviate coordinate measuring machine (CMM) bottlenecks.

When first introduced in the late 1970s, cutting tool coatings—especially titanium nitride (TiN)—were embraced by tool manufacturers for their ability to extend tool life. As workforce materials have expanded from conventional ferrous and nonferrous metals to exotic alloys, composites, ceramics, and others, coatings have likewise progressed and, thanks to new formulations and deposition methods, are extending cutting tool capabilities as well as tool life.

Manufacturing Engineering asked thought leaders at five companies for their views on challenges and trends facing the metalworking industry.

Q&A with Chirayu Shah, Marketing Manager, HMI Software, Rockwell Automation