Content By Ryan E. Day

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By: Ryan E. Day

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You might say what Henry Ford did for the automobile, GE, Siemens, and Mitsubishi have done for the gas and steam turbine industry. Naturally, the tools and technicians of both sectors have had to evolve right along with the challenges of new technology and the ever-increasing demands for improved accuracy and efficiency.

If you work in a facility that looks something like this:

you are probably familiar with machines that look like this:

If you’re familiar with steam turbines like the one seen above, then you certainly understand the fundamental challenges posed when they require internal alignment in the course of a maintenance or a major outage. The efficiency of today’s higher-rated turbines depends on precision alignment of components, and everything counts—nozzles, seals, bearings, and packing are all of critical importance.

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By: Ryan E. Day

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In today's hyper-competitive, fast-paced manufacturing world, there is rarely anything like a "routine" day at the office—especially when you're a tier-one supplier for some of the largest aerospace companies in the world. To make the grade and satisfy this kind of demanding customer base requires smarts, efficiency, hard work, and innovation. A little extra horsepower on the shop floor never hurts, either.

For that extra horsepower, EnCore Composite Structures of Brea, California, relies on the mobility, speed, ease-of-use, accuracy, and reliability of the FARO Edge ScanArm HD, a portable coordinate measurement machine (CMM) capable of both tactile probing and noncontact 3D scanning.

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By: Ryan E. Day

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In the most basic terms of engine exhaust theory, more flow equates to more performance. The aim is to improve the efficiency of your vehicle’s engine, boost performance, and save money on fuel. Auto-jet Muffler Corp. has implemented that “improved flow = improved performance” theorem on its shop floor and in its business model.

Headquartered in Des Moines, Iowa, Auto-jet has provided mandrel tube bending and aluminized 409, 304, and 316 stainless steel tubing for the OEM, construction, and agricultural equipment exhaust, truck exhaust, school bus exhaust, and off-road vehicle exhaust markets since 1959.

After decades of utilizing traditional manufacturing methods of tube bending, Auto-jet decided, for multiple reasons, that it could better serve its customers by utilizing 3D scanning technology.

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By: Ryan E. Day

Ihave never been accused of being an early adopter of cutting-edge technology. On the other hand, I don’t dance the Luddite jig, either. True to my own type, I hung on to my old M-1A tank, aka a Motorola flip phone, for as long as I could, but was pleased as punch when circumstances led me to adopt a true smartphone. I even splurged on a Bluetooth earpiece so I could combine business calls and commuting. I soon discovered that the decibel level inside a pickup truck rolling down I-5 far exceeds the capabilities of a personal Bluetooth device.

Major auto manufacturers have been offering Bluetooth-integrated sound systems for a few years now, but I suspect cabin noise presents problems for that option as well. I also suspect wind noise engineers at Ford Motor Co. have been hip to this for quite some time.

Working on the inside from the inside

Ford has long encouraged its employees to imagine—and develop—inventive solutions. One such innovation is manifesting in its core manufacturing business to make quieter automobile cabins. Hallelujah and pass the Bluetooth!

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By: Ryan E. Day

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W hen you work on projects like NASA’s Space Launch System and deep-space radio telescopes, the opportunity for accolades and large revenues can be great. However, due to the massive scale and demanding tolerances of such projects, the opportunity to have your lunch eaten by wasteful processes is also eminent. Janicki Industries is one company that has successfully addressed that problem.

Founded as Janicki Machine Design in 1993, Janicki Industries is a contract manufacturer to the aerospace industry specializing in aerospace tooling. Janicki Industries designs and builds high-precision parts and tooling for aerospace, marine, energy, space, military, transportation, and architecture customers.

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By: Ryan E. Day

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As global competition stiffens, manufacturing sectors of all stripes are embracing emerging technologies in order to meet customer demands. In the realm of metal casting, Pennsylvania-based Effort Foundry is leading the charge by investing in new technology as part of a continuous improvement program.

“Casting hasn’t really changed much in the last 1,000 years,” admits Michael Unmann, the director of machining operations at Effort Foundry. “But now we’re bringing in technology like solidification simulation, reverse engineering, and 3D scanning to prevent defects in our castings and advance our rapid prototyping capabilities.”

Preventing defects and avoiding what can be extraordinarily costly rework is the key to efficiency at an operation where single manufactured pieces can weigh up to a ton. The centerpiece of Effort Foundry’s newfound virtual modeling ability is their 3D scanning hardware and software.

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By: Ryan E. Day

No, they don't manufacture faucets, they don't run a major American airline, and they are not an elite special ops military unit. Headquartered in Taiwan, Delta Products Corp. is a global leader in switching power supply solutions, thermal management solutions, and DC brushless fans. Delta also earns "green" accolades the way Michael Phelps wins Olympic gold medals, so it's just natural that the company's new U.S. headquarters in Fremont, California, is designed to win platinum. LEED platinum, that is.

"Since 2005, all of Delta's new buildings around the world have been built to sustainable standards," says Bruce Cheng, Delta's founder and honorary chairman. "In the past 10 years, we have commissioned the construction and renovation of 21 green buildings and shared our experiences at this year's Conference of Parties, more commonly referenced to as the COP21."

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By: Ryan E. Day

The words “plastic,” “polymers,” and “environmental responsibility” rarely bump consonants in the same sentence, but public sentiment and keen competition can nudge a company into exploring all kinds of plastic substitutes. Of course, a $160 price tag on a barrel of oil is also rather compelling. So much so that the oil price shock of 2007, which saw prices climb to those astounding heights, breathed new life into Henry Ford’s original vision of “growing” automobiles.

Within a year of the oil price spike, one of Ford’s first green engineering wonders rolled off production lines: soy-based foam tucked into the seats of the 2008 Ford Mustang.

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By: Ryan E. Day

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I can tell you all about the California coast, its cultural and economic dynamics, my favorite hideaway beaches and eateries, and I can attest to the wisdom of never turning your back to the surf. I know these things because I've lived in The Golden State most of my life, but I've never ever been to Japan. All I know about its culture is what I’ve gleaned from the news, B movies about giant radioactive lizards, and books that espouse kaizen culture. Woefully inadequate insight when trying to understand and implement lean and kaizen training.

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By: Ryan E. Day

‘Would you care to participate in a quick survey to help us serve you better?” I suppose many people enjoy filling out surveys—their chance to sound off and all that. Personally, it’s not my favorite part of any transaction. Ford’s recent Customer Clinic in Irvine, California, though, was a different kind of survey.

Ford invited car owners to bring their vehicles and meet with vehicle engineers, as well as marketing and manufacturing teams, to discuss their experiences behind the wheel. The Irvine clinic convened customers who own 2015 Ford Mustang, 2015 Lincoln MKC and 2014 Ford Transit Connect automobiles to discuss topics including technology features such as SYNC, driver usability, design functionally, and product appearance.