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Reshoring Hub-Bub

By: James Callari 16. May 2013

 

Is reshoring fact or fiction? Morgan Stanley thinks the latter, so stipulated in a 125-page report titled U.S. Manufacturing Renaissance: Is It A Masterpiece Or A Fake? Basically the global financial firm says there is no data supporting claims that manufacturing is coming back to the U.S., calling any stories that suggest otherwise anecdotal.
 
But Harry Moser of the Reshoring Initiative is undaunted. Offshoring is indeed still occurring, the former machine tool executive agrees, but according to his group’s numbers,  some 50,000 manufacturing  jobs had been reshored in the time period from January 2010 through about July 2012, representing about 10% of manufacturing’s overall job growth. “The annual amounts are not large enough to be visible in national data.” Moser states. “The rate is still absolutely moderate, probably about as large as large as the annual incremental offshoring, but it is dramatically higher than 4 or 5 years ago,” he adds.
 
Taking a longer-term view, Moser points out that offshoring took 60 years to unfold with the help of many consultants and has resulted in a net loss of about 3 million manufacturing jobs. “Reshoring, conversely, has been underway for about 3-4 years and consultants are just starting to get onboard,” he states.  “The $500 billion+ trade deficit will eventually come down because our trading partners will stop shipping goods for worthless dollars. The question is whether the deficit comes down now gradually as companies recognize total cost and improve productivity or later dramatically when the dollar collapses. I prefer the former.”
 
Moser adds: “The key for faster reshoring is for companies to reevaluate their offshoring decisions using something like our Total Cost of Ownership Estimator, see that the true cost gap is gone in some cases and small in others, apply lean, automation, training, etc. to close the remaining gaps as costs continue to rise offshore. Given the difficulty of achieving cultural change, that process will only accelerate now if the media consistently reports on the reshoring successes. Companies followed each other like lemmings offshore. My job…is to shine a light on the cases that will motivate the herd to reevaluate and the tools that will help them decide to come home.”

 

Top 10 Troubleshooting Tips

By: James Callari 29. April 2013

I usually don't venture into the realm of "technical" in this space. I leave that up to my fellow blogger Tim Womer. But well-known extrusion gurus Greg Campbell and Mark Spalding announced at ANTEC last week the publication of their 800-page book,  Analyzing and Troubleshooting Single-Screw Extruders. Six years in the works, the book is chock full of processing advice and should be on the shelves of anyone involved in the extrusion business.

I do like Top 10 lists, however. Click here for a quick summary of what the two authors have identified as the Top Ten list of troubleshooting tips, posted originally on the SPE's Extrusion Division website.

Click here for information on how to order the book.

PPA Adds Three New Members

By: James Callari 11. March 2013

The Plastics Pioneers Association this month announced that three new members have been selected to join the organization.
 
Founded in 1944, the PPA is a non-profit organization with a roster of more than 250 members, all of whom have at least 25 years of experience in plastics. The group’s primary purpose is to award scholarships to students seeking a career in plastics and to preserve the history of the industry. Plastics Technology Executive Editor Matthew Naitove as well as yours truly are among the members, as is Rick Kline, CEO of Gardner Business Media, parent compant of PT.
 
The new inductees are:
 

Dennis Paradise: Paradise has been in plastics machinery sales since 1986, when he joined McNeil Akron as sales manager. Since then he has worked in a variety of sales positions for Krupp Machinery, HPM, Dynisco, and Extrusion Dies Inc.

Dennis is currently senior vice president of sales and marketing for Processing Technologies Inc., a global supplier of sheet extrusion systems based in Aurora, Ill. During his career Paradise has served on the regional advisory board of the SPI and has presented papers at numerous conferences around the world. He is also a member of the Society of Plastics Engineers. Dennis graduated from Kent State University in 1976 with a BS in business administration.

 
John Perdikoulias:  Perdikoulias joined the plastics industry in 1985, when he went to work for Brampton Engineering as an R&D engineer. In his 12-year stint at Brampton he designed more than 200 single-layer and more than 100 coextrusion dies for blown film. One of the more significant products that Perdikoulias helped commercialize is Brampton’s stacked-type die, called the Streamlined Coextrusion Die. His work ultimately lead to the sale of the first commercial 8- and 9-layer dies in the world, which have helped make Brampton a global leader in coextrusion blown film extrusion systems.
 
Perdikoulias co-founded Compuplast in 1989, where he currently serves a president. At Compuplast, Perdikoulias has developed some of the most advanced CAE tools that more than 200 companies around the world use for the design and optimization of polymer processing equipment.  
 
Perdikoulias earned both his bachelors’ and masters’ degrees in chemical engineering from McMaster University in Hamilton, Ontario. He received his PhD in chemical engineering in 1997 from the University of Waterloo.
Perdikoulias has been an active member of both the SPE and TAPPI for virtually his entire career.
 
In 1997, he received the best paper award for his presentation at ANTEC. He also received the TAPPI PLACE Technical Achievement Award and Best Paper award in 2004. He also recently received designation as an Honored Service Member of SPE.
 
Mark Spalding has spent his entire 28-year career working in R&D for Dow Plastics. Over that span he has held a number of technical positions in corporate R&D, polystyrene R&D, plastics R&D, and INCLOSIA Solutions.
 
Spalding is widely considered an expert in single-screw extrusion and related polymer processing technologies. He has solved some of the most complicated extrusion problems at Dow customer’s plants by developing and applying sophisticated troubleshooting methods. These solutions have created considerable value to both Dow and to Dow’s customers. Mark has designed extrusion systems for most of Dow’s major customers for virtually every resin that Dow produces.
 
Spalding has been involved with the SPE throughout his career. He has served as technical program chairman for SPE’s ANTEC Conference in 2008, 2009, 2012, and 2013. He served on the SPE’s Fellows Selection Committee in 2004, 2005, 2006, 2007, and 2013. He has been a board member of the SPE’s Extrusion Division since 1999, having served as chairman in 2004-2005. He is also a member of the Polymer Processing Society.
 
He was elected an Honored Service Member SPE in 2011, and a Fellow Member in 2003. He also received the Bruce Maddock Award from the Extrusion Division in 2006 and six times received the Best Paper Award at ANTEC.
 
Spalding completed a book to be published by Hanser in April 2013 titled Analysis and Troubleshooting of Single-Screw Extruders. The book is 700 pages; the first half provides the fundamental theory of extrusion based on screw rotation physics, the second half contains nearly 100 actual case studies on extrusion problems and their technical solutions. Prof. Gregory A Campbell is coauthor.
 
He received his B.S. in chemical engineering from the University of Toledo in 1979, his M.S. in chemical engineering from Purdue University in 1982; and his Ph.D. in chemical engineering from Purdue in 1985.
 
Paradise, Perdikoulias and Spalding will be inducted at the PPA’s spring meeting, scheduled for April 11-13 at the Omni Hotel on Hilton Head Island. S.C.

Register Now for amerimold

By: James Callari 1. March 2013

Exhibit hall and conference registration is now open for amerimold 2013—The The Event for Mold Manufacturing –taking place June 12-13, 2013, at the Donald E. Stephens Convention Center in Rosemont, Ill.
 
amerimold is North America’s premier event for mold manufacturing. Presented by Gardner Business Media, in partnership with MoldMaking Technology, Plastics Technology and Modern Machine Shop, amerimold connects global and domestic technology leaders involved in all aspects of mold manufacturing.
 
Complimentary exhibit hall pre-registration extends through May 1st, 2013, and includes:
  • Exhibit Hall Pass: Full access to the amerimold exhibit hall
  • Technical Education: Admission to show floor technical presentations
  • Additional Events: Complimentary access to co-locating SUR/FIN and FastenerTech 
 
Learn more here. 
 
For more information, contact Anne Von Moll, registration manager.

A New Level of Automation

By: James Callari 26. February 2013

Rodon Group, the Hatfield, Pa. injection molder that has long relied on automation to produce parts “cheaper than China,” as its website extols, is among the first plastics processors to deploy Baxter, a new kind of robot developed by Rethink Robotics, Boston, Mass.
 
Rodon will be using Baxter for repetitive tasks like picking up parts off a conveyor for packaging. The robot can be "trained" by the very people it is assisting. With extra sensors to make Baxter “aware” of his surroundings, it can be deployed near people. Not bothered by heat or noise, Baxter can take on those “hard to fill” positions.
 
Baxter contains a suite of integrated sensors and a basic knowledge of how to perform a wide range of simple manufacturing operations.
 
Baxter can be tasked with the general part movement. It can transport parts from one location to another, count, re-orient and much more. Baxter can put parts onto moving conveyors or fixed surfaces, or remove them from moving conveyors or fixed surfaces. It can check parts for characteristics like weight or shape, evaluate against criteria and perform different actions depending on test results.
 
Baxter can tend machines and perform operation sequences based on stimuli. For example, it can be trained to place a part in a machine and push a button.It can systematically pack a bag, box or tray. It can be trained to arrange packed objects in an array and unpack containers. Baxter can be trained to align and snap fit assembly elements and insert items into containers, and can grind, polish and perform other finishing operations on a variety of parts and materials.
 
Rethink Robotics was founded in 2008 by robotics pioneer Rodney Brooks. Brooks  was a co-founder of iRobot and held positions there including CTO, Chairman and board member from 1990 through 2011.
 
From 1984 through 2010, Brooks  was on the faculty of MIT as the Panasonic Professor of Robotics, and was the director of MIT CSAIL, the Computer Science and Artificial Intelligence Laboratory. While at MIT, Rod developed the behavior-based approach to robotics that underlies the robots of both iRobot and Rethink Robotics.




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