Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Maintenance for Manufacturing Maintenance for Manufacturing Maintenance for Manufacturing Maintenance for Manufacturing Maintenance for Manufacturing Maintenance for Manufacturing Maintenance for Manufacturing Maintenance for Manufacturing Tampa Bay Mechatronics Forum Tampa Bay Mechatronics Forum February 2014 February 2014 Principal Campbell Management Services, LLC [email protected] – www.campbellmanagementservices.net Keith S. Campbell Director, Industrial Maintenance Training Center www.imtcna.org
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Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Mechatronics & Industrial Maintenance for ManufacturingMaintenance for ManufacturingMaintenance for ManufacturingMaintenance for ManufacturingMaintenance for ManufacturingMaintenance for ManufacturingMaintenance for ManufacturingMaintenance for Manufacturing
Tampa Bay Mechatronics ForumTampa Bay Mechatronics ForumFebruary 2014February 2014
� Process manufacturing� Efficiency driven: long runs of things in pipes� Efficiency driven: long runs of things in pipes� Chemical transformation� Oil refining, casting, paper making� Process control, DCS’s, PID
� Similar to non-manufacturing segments mineral extraction and utilities� Hybrid manufacturing
� Combination of process and discrete possibly with batch operations� Physical transformation� Often have large packaging operations� Consumer goods, food, beverage, pharmaceuticals� Sometimes use different automation strategies and different engineering and
maintenance teams in different ends of the plant4
US manufacturing segmentsUS manufacturing segments
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Technical Skills Vary by Segment Technical Skills Vary by Segment There isn’t a one-size-fits-all solution
Common core skills – math, electricity, mechanics, motors
Industrial Maintenance & Mechatronics is Industrial Maintenance & Mechatronics is Industrial Maintenance & Mechatronics is Industrial Maintenance & Mechatronics is important (but different) for each segmentimportant (but different) for each segmentimportant (but different) for each segmentimportant (but different) for each segment
� Manufacturing jobs have leverage� Largest economic and job multiplier effect of all industry sectors,
each supporting 2 supply chain jobs and 2 consumer sector jobs� Skilled manufacturing jobs have even more leverage, sometimes
credited with supporting 7 to 11 other jobs credited with supporting 7 to 11 other jobs � Industrial Maintenance Jobs have the highest leverage
� In central PA, we lost over 300 production jobs for lack of 40 maintenance technicians
� A skilled technician can keep one line working over 3 shifts� A skilled technician can have tremendous impact on OEE
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Definition of MechatronicsDefinition of MechatronicsDefinition of MechatronicsDefinition of MechatronicsDefinition of MechatronicsDefinition of MechatronicsDefinition of MechatronicsDefinition of MechatronicsThe synergistic application of:
Computer ScienceMechatronics
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to create useful products.
Mechanical Engineering
Electrical Engineering
Controls Engineering4 legged stool definition
Mechatronics & Mechatronics & ManufacturingManufacturingA Paradigm Shift A Paradigm Shift A Paradigm Shift A Paradigm Shift A Paradigm Shift A Paradigm Shift A Paradigm Shift A Paradigm Shift for Equipment Design & Maintenancefor Equipment Design & Maintenancefor Equipment Design & Maintenancefor Equipment Design & Maintenancefor Equipment Design & Maintenancefor Equipment Design & Maintenancefor Equipment Design & Maintenancefor Equipment Design & Maintenance
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Moving part Moving part count reductioncount reduction••Pulleys Pulleys -- 45 45 to to 00••Belts Belts -- 15 15 to to 00••Drive sprocketsDrive sprockets -- 15 15 to to 00••SplineSpline shafts shafts -- 2 2 to to 00••GearboxesGearboxes -- 16 16 to to 1010••MotorsMotors -- 1 1 to to 1010••BearingsBearings -- 18 18 to to 33••Line shaftsLine shafts -- 6 6 to to 00
TotalTotal -- 118 118 to to 2323((8181% reduction% reduction)) Case Study in Mechatronic DesignCase Study in Mechatronic DesignCase Study in Mechatronic DesignCase Study in Mechatronic Design
Evolution from a PLC-controlled electro-mechanical machine to a mechatronic machine.Courtesy of R.A. Jones Packaging, General Mills, Inc., OMAC Packaging Workgroup
Mechatronics in ManufacturingA dramatic shift for industrial maintenance
� Enabling for existing industry (manufacturing, farm equipment)� Foundational for emerging industry (photo-voltaics, wind)� World-class manufacturers require integrated mechatronic machinery
designs to be competitive� You can’t put multiple technicians on an airplane or have six prima donnas arguing over whose fault it is that the plant isn’t producingdonnas arguing over whose fault it is that the plant isn’t producing� Operations and maintenance requires new thinking
� More / different technical skills required of operators� An (r)evolution is taking place from multiple crafts (electrician, mechanic,
programmer, instrument technician, etc) to multi-skilled industrial maintenance technicians
� Electro-mechanical technician� Advanced Manufacturing / Integrated Systems Technician – AM/IST� The capstone of this is the mechatronics technician
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Mechatronics impacts all levels� Engineering science – trapped in our silos.� Engineering technology – first program at Purdue, emerging
slowly� Technicians – community college degree and certificate
programs, vo-tech programs, incumbent worker training� Lots of jumping on the bandwagon as funding became available� Lots of jumping on the bandwagon as funding became available� Many are electro-mechanical programs� Finding appropriate breadth and depth of skills � Programs need to be focused to careers
� Product vs plant focus� Design, assembly, troubleshooting & maintenance� Discrete, hybrid, process segments
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Meeting Regional NeedsMarketing 101
� Know your customer� Know your consumer� Deliver value to each
� Where they want it� Where they want it� When they want it� How they want it
� Build solutions to satisfy the market need
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Example - Confectionery Bars� Very different customers with needs for different service
The Credentials Conundrum� Credentials are common in healthcare, transportation,
other areas� When asked, most manufacturers will say they don’t care
about credentials� Concerned about employee mobility� Concerned about lack of quality – too often lowest common � Concerned about lack of quality – too often lowest common
denominator / one-size-fits-all solutions� Today, programs funded with federal $’s are REQUIRED
to provide an industry recognized credential� $1/2 billion recently granted for manufacturing programs
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The Credentials Conundrum� Metalworking segment has most access to credentials� Few choices in industrial maintenance and mechatronics
� NIMS for basic machine tool maintenance� Siemens Mechatronics, using the German educational model� PMMI, emerging using a US model� Industrial Maintenance Training Center� Industrial Maintenance Training Center
� Advanced Manufacturing/Integrated Systems Technician � US DOL Mechatronics Competency Model� PMMI competencies and certification program
� This is a challenge for schools� The easy alternatives
� Lowest common denominator certificates� Default to existing certificates, letting 2/3 of manufacturers out
� Florida will have to address the credentials issue, while meeting the regional needs of customers and consumers
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PMMI Certificate ArchitectureSk
ill Le
vel
HGJILKNM
Hybrid Manufacturing Mechatronics Certificates
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Manufacturing Continuum
Process DiscreteHybrid
Skill
Leve
l
FEDCBAHG
Operative Skills MSSC NIMS
Industrial Maintenance Training Center CredentialsYellow AM/IST 1 –entry level electro-mechanical technicianBlue AM/IST2 –senior electro-
Success factors to consider� Ask the best of the best, listen, understand. Look over
the horizon.� Regional strategic advisory board for vision, local
industrial advisory boards for tactics.� Focus public resources on the top 1/3 of
manufacturers. manufacturers. � Recognize that these programs are expensive. � Adults first – it pays the overhead and insures quality� Use the public education system for industrial training,
forcing it to catch up.� Provide a path to college credit for workforce training
and already mastered skills. No repeating.24
Success factors to consider� Sell credentials to minimize customization� Provide training when and where needed without fixed
start and end dates. � Collaborate and articulate credit amongst schools.
Facilitate student movement from school to work to � Facilitate student movement from school to work to school.
� Reject lowest common denominator solutions. Target needs specific to industry segments.
� Hands-on experience with real industrial equipment and documentation; labs, labs, labs.
� Teach and practice troubleshooting as a discipline.25
Success factors to consider� Provide stackable industry credentials that provide
early & intermediate achievement and exit points.� Focus on infrastructure and delivery. There is more
than enough curriculum. New credit hour / contact hour model may be required. � New credit hour / contact hour model may be required. Typical 30 – 40 lab hours / credit.
� Utilize modular e-learning to the fullest.� Plan and deliver across conventional departments.
� The earliest point of failure� Create a 2+2+2 model to align high school, community
college, university and work.26
Thank-you!Campbell Management Services LLC
� Bridging the gapsBridging the gapsBridging the gapsBridging the gaps between:� People & technology� Technology & business
