assembly - 08 aug 2009

Auto Supplier Rides Winds

of Change pg 14

Ophthalmic Assembly 22

Marking Dots, Stripes 30

Selective Soldering 34

ATExpo Preview 37

ASSEMBLYwww.assemblymag.comAugust 2009

See us at ATExpo, Booth 507

Be the first to experience the future of precision fluid dispensing.

ATExpo, Booth 705


Automating Battery Assembly

Robot Guidance

Assembling With Lockbolts

Assemblers Get a Lift

Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Time to back health care reform.—John Sprovieri

Automation Profiles . . . . . . . . . . . . . . . . . . 8System handles fragile components.—John Sprovieri

Quality in Assembly . . . . . . . . . . . . . . . . . . 9Software helps assemblers manage quality tasks.—John Sprovieri

We Fed It . . . . . . . . . . . . . . . . . . . . . . . . . . . 10System feeds, assembles springs.—John Sprovieri

New & Noteworthy . . . . . . . . . . . . . . . . . . 12All-purpose gloves made from bamboo.

Assembly Lines . . . . . . . . . . . . . . . . . . . . . 16Group launches wind energy data base.

Assembly in Action . . . . . . . . . . . . . . . . . . 18Single-cable camera maximizes efficiency.

Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Classified . . . . . . . . . . . . . . . . . . . . . . . . . . 46

� Automotive Supplier Rides Winds of ChangeWhen a Nevada startup went looking for a

manufacturer to assemble a new type of wind turbine,

automotive supplier MasTech Manufacturing leapt at

the opportunity.—John Sprovieri

� Better One or Better Two?Ophthalmic device manufacturers keep an eye on new

technology.—Austin Weber

� When All You Need Is a DotMarking parts with colored inks or stains is a fast,

easy way to differentiate between similar-looking

components, indicate pass-fail status or confirm that a

specific process has been performed.—John Keating

and Claude Bergeron

� Riding the Mini WaveAutomated selective soldering technology saves EMS

facilities time and money.—Reed Gaither

� Don’t Miss the Big ShowFind the tools your company needs to succeed at

ATExpo 2009.—Adam Cort

COVER STORY

FEATURES DEPARTMENTS

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66ASSEMBLYAugust 2009 Vol. 52, No. 9

2 ASSEMBLY / August 2009 www.assemblymag.com

22

14

30

34

37

Cover photo courtesy Mariah Power

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Recently, while cutting some fruit for breakfast, I

nearly sliced off the tip of my left index finger. After

much bleeding, abundant foul language, and a trip to

the emergency room, I’m happy to report the finger was

saved.

Including a tetanus shot and skin glue, the bill for my

mishap totaled an astounding $982. I shudder to think of

the bill had I been in a serious accident. Thankfully, I have

health insurance, but how long will that continue when

treatment for a simple cut costs nearly $1,000?

Almost all U.S. manufacturers offer health benefits to

their employees, but the rising cost of those benefits is impairing their ability

to hire workers, battle overseas competitors, develop new products, and invest

in assembly technology. Employer-sponsored health insurance premiums have

nearly doubled since 2000, a rate three times faster than wages. In 2008, the

average premium for a family plan purchased through an employer was $12,680,

which is nearly the annual earnings of a full-time minimum wage job. According

to a 2008 survey conducted by the National Association of Manufacturers, 55

percent of small and midsized manufacturers reported that their health care costs

increased by more than 10 percent during the past year.

The 2008 election seems finally to have goaded Congress to action. In July,

the House and Senate released draft reform bills. The bills are too big to be

elaborated here, but here are a few key provisions.

People who get insurance through their employer would retain that coverage.

A new Health Insurance Exchange would be created so small employers and

uninsured individuals could comparison shop among private and public insurers.

Over time, the exchange would be opened up to all employers as another

choice for covering their employees. Premium subsidies would be provided to

individuals and families with low and moderate incomes.

The measure is expected to cost $1 trillion over 10 years, a sobering number to

be sure. It will be paid for with a mix of tax hikes and spending cuts on programs

like Medicare. The House plan would apply an income tax surcharge on the

wealthiest Americans. Another possibility is to limit the tax exemption on the

most expensive health benefits plans from employers.

Just as there can be no one solution to our increasing energy demands, health

care reform must take a multipronged approach to the myriad factors that drive

up costs. That means legislators on both sides of the aisle must swallow some

bitter medicine. Sorry, Democrats, tort reform must be part of the health care bill.

Too bad, Republicans, but a public option should be included in the insurance

exchange.

Whatever bill emerges from Congress—and we must demand a legitimate

proposal this year—manufacturers should get behind it. The worst we can do

is nothing.

Time for Health Care Reform

Editorial ASSEMBLY 1050 IL Route 83, Suite 200Bensenville, IL 60106-1096

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H andling glass can be challenging for any automation project.

Actuators and grippers have no appreciation for the delicacy

of an object. Glass parts in the wrong place at the wrong

time are no match for hardened steel.

Allied Automation has designed several systems that process

thin glass containers safely and effi ciently at high speeds. So when

a medical manufacturer approached Allied to build a system to as-

semble an adhesive applicator, the company knew how to get the

job done.

Besides the adhesive itself, the applicator consists of a plastic

swab tube, a glass ampoule and a plastic fi lter tip. A solvent bonds

the fi lter to the tube. The ampoule is only 0.004 inch thick and

very fragile. In this profi le, Allied’s president, Jeff Graham, and

engineering manager, Nathan Marshall, describe how the machine

works.

For more information, visit www.alliedautomation.com or call

919-362-4440.

Describe the system. The machine has two components: an

eight-station rotary dial and a recirculating puck conveyor. The

dial is equipped with removable nests that hold four parts each.

Each puck carries eight parts, and the conveyor accommodates 800

parts.

The fi rst station places four tubes in a nest and inspects for them

presence and height. The second station lifts the tubes, supports

them from the inside, and punches vent holes, depending on the

product. (A product variant does not require vent holes.)

The third station gently places the ampoules into each tube.

Tooling at this station confi rms the presence, length and integrity

of the glass. At station four, the fi lters are pressed into the tubes to

complete the assembly and retain the ampoule.

The fi fth position was intentionally left free of tooling to fa-

cilitate access to the machine for cleaning and maintenance—an

often-overlooked part of sound machine design.

The sixth position inspects and records the assembled height of

the product. This is done with linear variable displacement trans-

ducers.

At station seven, good assemblies are off-loaded to the conveyor,

where the solvent is applied and cured. The solvent is dispensed

with a resolution of ±0.1 microliter. Bad assemblies are indexed to

station eight, where they are deposited in a bin.

What are the dimensions of the assembly? The machine han-

dles two different product sizes. One is 52 millimeters long; the

other is 72 millimeters long. Both are 8 millimeters in diameter.

What equipment feeds the parts? Vibratory bowls with bulk

hoppers feed the tubes and fi lters. The ampoules are fed manually.

We also had to develop innovative ways to deal with the static elec-

tricity generated when feeding thin plastic parts.

What inspections are included? All parts of the assembly

are inspected for presence, orientation and assembled height.

Inspections are performed with photoelectric sensors, capacitive

proximity sensors and linear encoder-based contact probes.

Additional sensors monitor the level and displacement of solvent,

as well as the correct position of every actuator on the machine

during operation.

What is the production rate? 4,200 parts per hour. Only two

people operate the entire system.

Can the system accommodate variants? The system han-

dles two different product sizes both with and without vent

holes. Changeover is fully automatic. The product to be as-

sembled is selected through the touch-screen, and all machine

adjustments are made automatically.

What was the most challenging aspect of building the sys-tem? The system must handle an ampoule every second without

breaking any, and it must be easily accessible for cleanup when

ampoules do break. It was critical to the success of the project that

we understood that glass and adhesive can and will get everywhere

that you do not expect it.

We used chemical- and corrosion-resistant materials

throughout the machine. The system is enclosed with tem-

pered safety glass, so the windows stay clear even after

cleaning with aggressive chemicals. All pneumatic actuators

are equipped with corrosion-resistant rods. The system also

had to comply with FDA requirements and clean-room speci-

fications. A

Editor’s note: Whether you’re a systems integrator or the in-house automation team of an OEM, if you’ve designed a system that you’re particularly proud of, tell us about it. Send an e-mail to John Sprovieri, editor of ASSEMBLY, at [email protected], or call 630-694-4012.

System Handles Fragile Components

When designing this system to assemble an adhesive applicator, engineers knew that glass and adhesive can and will get everywhere that they do not expect it.

The glass ampoule is only 0.004 inch thick and very fragile.

AutomationProfi les

I n these days of far-flung supply chains and

multiple assembly locations, even small and

midsized manufacturers can have difficulty

keeping everyone in their organizations on the

same page. If a new standard or regulation affects

your assembly process, can you be certain every-

one gets the message? If an assembly-related

defect is reported in the field, can you be sure the

mistake isn’t repeated?

You can, with web-based enterprise compli-

ance and quality management software, says

Nikki Willett, vice president of marketing and

regulatory affairs at

Pilgrim Software in

Tampa, FL. Pilgrim’s

product consists of

seven interrelated,

customizable modules

that cover audit man-

agement, training and

certification, calibra-

tion and maintenance,

suppl ier qual i ty,

document manage-

ment, complaint han-

dling, and corrective

and preventive action

(CAPA) management. A key feature is the soft-

ware’s ability to integrate with other software,

such as enterprise resource planning systems,

manufacturing execution systems, product life

cycle management software, human resources

software, and call-center systems.

The top priority of any manufacturer is to

address quality problems whenever and wher-

ever they occur. The CAPA management module

captures these problems from multiple sources.

“It can be a customer complaint,” says Willett. “It

can come from your MES, because of a problem

on the shop floor. It may be an issue with incom-

ing parts from a supplier. It may come from a

piece of equipment that’s out of spec.”

When a problem is identified, a number of

decisions need to be made quickly. Does the pro-

duction lot need to be contained? Has it already

entered the distribution pipeline? Software tracks

it down. In the case of a medical device, the soft-

ware can also generate an electronic report for

the Food and Drug Administration.

At that point, managers can think about iden-

tifying the root cause of the problem and how to

correct it. Say, for example, an operator was using

a machine incorrectly because the work instruc-

tions were out of date. The CAPA module can

trigger a request to update the instructions in the

document management module. The “owner” of

the document would know to update the instruc-

tions and get any necessary approvals.

When the updated instructions are logged into

the system, the training and certification module

is alerted to ensure that every operator who uses

that machine knows the new procedures. This

can be as simple has having each operator sign

off on the new instructions. “Or, you may want to

have the manager confirm that the operators have

read it,” says Willett. “Operators may have to go

through a checklist or take a small exam. They

may even need classroom or online training.

...And because our software can be integrated

with other business software, employee records

can be automatically updated to reflect that they

have completed the training, which they may

need for their job certification.”

Perhaps the cause of the problem wasn’t an

outdated work instruction, but a machine that

was out of specification. The calibration and

maintenance module can tell management when

the machine was last calibrated or serviced, and

it can notify maintenance personnel to make an

adjustment or replace a part.

If the problem was faulty parts from a supplier,

the supplier quality module gets triggered. “That

could impact the rating of the supplier,” says Wil-

lett. “You may want to requalify that supplier. You

may even want to change suppliers.”

If ISO or FDA certification is necessary, the

audit management module can help engineers

prepare for audits and deal with their findings.

“Auditors will come through with their ques-

tions and checklists,” says Willett. “They may

find some issues and...make recommendations

for improvement. Engineers can use the soft-

ware to enter their plans for correcting those

issues. Some of the auditor’s findings may be so

critical that engineers may want to escalate to a

CAPA.” A

Software Helps AssemblersManage Quality Tasks

QUALITY in ASSEMBLY

■ By John SprovieriEditor

When updated instructions are logged into the system, the software alerts every operator to the new procedures.

Web-based enterprise compliance and quality management software can help assemblers address quality problems whenever and wherever they occur. Photo courtesy CEA

Technologies Inc.

www.assemblymag.com August 2009 / ASSEMBLY 9

For reprints of this article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.


System Feeds, Assembles Springs� By John Sprovieri

Editor

The Versa-Stack consists of a servo-driven rotary indexer with a custom dial plate. Mounted radially around the edge of the plate are pins for holding tubular parts. Photo courtesy Centricity Corp.

www.schleuniger-na.com/tm_am(603) 668-8117

Our Box Makes It Easy

Schleuniger’s semi and fully automatic transfer systems deliver completed, tested cable assemblies within seconds.

TransferModule 1500

TransferModule 6000

Curious?

asb08094schl.indd 1 7/6/09 3:07:12 PM

S prings are tough to feed. They’re fl exible,

and they tangle easily. Centricity Corp. has

developed a machine, called the Versa-Stack,

that overcomes the challenges of feeding and

assembling springs and other tubular parts.

Recently, the machine was put to the test. It had

to stack three cylindrical parts—a ring formed from

steel wire, a metal tube, and a small or large coil

spring—and place the stack into a larger assembly.

The OD of each part was approximately 0.15 inch;

the ID was 0.1 inch.

The Versa-Stack consists of a vertically

oriented servo-driven rotary indexer fitted with

a custom dial plate. Mounted radially around the

edge of the plate are 35 replaceable pins. Above

the plate are two vibratory bowl feeders and two

spring feeders fitted with Centricity’s Feedscape

systems.

The Feedscape is designed to feed parts with

a high diameter-to-length ratio, such as washers,

retaining rings, wave washers, Belleville springs,

seals and bearings. Instead of handling parts by

their outer surfaces, it handles parts by their inside

surfaces. The parts are threaded onto a rod and

secured by a series of alternating jaws. Parts are

free to travel down the rod as the jaws open and

close. This maintains control of the part at all times.

There is no chance for parts to fl ip, shingle or fall

off. The Feedscape does not require a vibratory in-

line track, and tooling is inexpensive and fl exible.

As the dial indexes clockwise to the 11:00

position, a ring is fed from the bowl to a Feedscape,

which drops it onto a pin. The dial then indexes to

the next position, where the tube is dropped onto

the same pin. Next, the dial indexes to the fi nal

position, where the small spring is dropped onto

the pin. If the assembly requires the large spring,

the fi rst spring feeder is bypassed and the second

feeder is activated.

The stacks are held in place by an integrated

retaining system until they reach the 6:00 position.

At that point, the stack is threaded onto another

Feedscape mechanism, which passes it off to a

robot at a rate of 15 per minute.

For more information, call 330-545-5624 or

visit www.centricity.net.


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Gloves Made of BambooGO Greens all-purpose coated work gloves are strong, functional, reusable

and washable. When bamboo is spun into a fiber, it makes for a fabric that

is as soft as silk. Because bamboo naturally creates an antibacterial com-

pound called “bamboo Kun,” the gloves are both hygienic and remain fresh

even after extensive hard use. Bamboo fabric is also highly absorbent and

wicks water away from the body three to four times faster than cotton. As a

result, the gloves keep an operator’s hands drier, cooler and more comfort-

able. GO Greens are also hypoallergenic and 100 percent biodegradable.

They decompose without creating any pollutants, such as methane gas, a

common byproduct of decomposition in landfills and dumps.

Gloves-Online Inc919-468-4244www.gloves-online.com

New Robots Have Speed, ReachThe new TS series of high-speed SCARA robots is available with reaches

of 400 millimeters, 600 millimeters and 800 millimeters. It can accom-

modate payloads up to 8 kilograms. All TS series robots feature four

degrees of freedom, a hardened plastic external housing and electric servo-

driven motors for reliability. The robots are highly adaptable and well

suited for use in a variety of precision high-speed applications, including

pick-and-place, material handling, packaging, assembly, loading, testing

and dispensing. The robots employ the CS8C controller, which features

a compact lightweight design and can be easily integrated into a large

production system.

Stäubli Robotics USA846-433-1980www.staublirobotics.com


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Meter-mix Systems Fill Many NichesMeter-mix systems are available for everything from dispensing

micro shots to high-volume applications, such as potting, bead lay-

ing, form-in-place or filling. They can accommodate a wide range of

materials, including adhesives, polyurethanes, resins and epoxies,

and are easy to integrate with either a larger automated system or

tabletop robot. Systems can be uniquely tailored for any ratio or

fluid combination at an affordable price, and come with a guarantee

of service.

I&J Fisnar Inc.201-796-1477 www.ijfisnar.com

Modular Automatic Coiling System Is FlexibleThe modular AutoCoiling System can automatically coil, bind

and batch long wires, replacing lengthy conveyors and freeing

up valuable floor space. Due to its flexible and modular design,

including a separate power supply, the system can be retrofitted

to CrimpCenter series machines in the field. It is possible to coil

single-wire applications with or without seals or terminals on either

end. Accuracy is assured by continuous wire length measurement

using a closed-loop system.

Schleuniger603-668-8117www.schleuniger-na.com


NEW &


Automotive Supplier Ridesthe Winds of Change

N ot that long ago, MasTech Manufacturing in Manistee, MI, was

riding high. A supplier of conveyors, material handling equip-

ment and welding cells for the automotive industry, the com-

pany had won some major contracts, including lines at Freightliner in

Cleveland, NC, and BMW in Spartanburg, SC.

But then the automotive industry hit the skids. MasTech’s work-

force went from approximately 50 people in mid-2008 down to just

three. If the company were to survive, it would have to diversify. So,

when Reno, NV, startup Mariah Power went looking for a manufac-

turer to build its new wind turbine for residential and light commercial

use, MasTech leapt at the opportunity.

It signed a contract with Mariah Power in December 2008, and be-

gan converting its 30,000-square-foot facility to make the turbine, a

vertical-axis design called the Windspire. All totaled, MasTech spent

some $1.5 million on new equipment. “We built robotic [and] manual

welding tools,” says John Holcomb, MasTech’s general manager. “We

built custom material handling equipment and racking. We bought

new machine tools.”

Production began in April. Since then, the company has been

assembling 100 turbines per month—a number that could increase to

1,000 per month within a few years. MasTech has shipped Windspires

throughout the United States, as well as internationally, including

Israel, Denmark, France and the Netherlands.

The company has hired back all the employees who were laid off,

and even added a few more. By the end of 2009, the company could

have a workforce of 75 to 80 people. “By the end of next year, we

hope to employ approximately 120 people,” says Holcomb. “If we

start selling more overseas, we could potentially have 500 to 600 jobs

in fi ve years.”

The Windspire is 30 feet tall and 4 feet wide. It includes a high-

effi ciency generator, an inverter, a hinged monopole and a wireless

performance monitor. The 1.2-kilowatt machine will produce approxi-

mately 2,000 kilowatt-hours per year in winds averaging 12 mph.

From the start, MasTech included local suppliers in the endeavor.

The turbine’s aluminum airfoils are produced by Whitehall Industries

Inc. in Ludington, MI. Steel parts come from Alro Steel Corp. in

Jackson, MI. The inverters are assembled by Amptech Inc. in Free

Soil, MI. Boxes and crates are made by Norton Packaging Corp. in

Grand Haven, MI. At least three other Michigan companies are also

part of the supply chain.

“It’s been our desire since Day 1 to make the largest economic impact

in the smallest geographical area,” says Holcomb. “The only components

that come from outside the United States are the rare earth magnets, which

come from China, but that’s where neodymium is mined.”

Holcomb emphasizes that his company’s turnaround should not be

considered unique. “We’ve proven that, given the right tools and the right

attitude, American workers can compete in the global market by supplying

not only a cost-effective product, but a superior product,” he says. “Anyone

can do it. We have the technology. If we reapply it and leverage it in new,

innovative directions, we can compete with anybody.” A

Editor’s note: With all the news of bailouts, layoffs and plant closings, it’s all too easy to think every manufacturer is stuck in the doldrums. In fact, there’s plenty of good news in manufacturing—if you take the time to look. “Moving Forward” is dedicated to new or expanding assembly plants. If you know a facility that’s opening, growing, investing in new equipment, or simply going great guns while everyone else is treading water, we’d like to hear about it. Send an e-mail to John Sprovieri, editor of ASSEMBLY, at [email protected], or call 630-694-4012.

“It’s been our desire since Day 1 to make the largest economic impact in the smallest geographical area.”—John Holcomb, MasTech

Since April, MasTech has been assembling 100 turbines per month—a number that could increase to 1,000 per month within a few years. Photo courtesy Mariah Power

� By John SprovieriEditor


2 people. 1 tool. Infinite configurations.2 people. 1 tool. Infinite configurations.

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of people with a Phillips screwdriver can build exactly what you need. The unique

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Adder modules let you easily set up a workstation

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Full AdaptabilityThe Arlink 8000’sDefinite PositioningSystem allows easy,secure placementand reconfigurationof accessories.

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Experience a detailed, interactive overview of the Arlink 8000 workstation’sinnovative, time-saving features. Visit www.arlink6.listaintl.com

Deere & Co. Planning Russian Expansion

MOLINE, IL—Deere & Co.

says it is prepared to “signifi cantly

expand its farm, forestry and con-

struction operations in Russia,” as

part of the company’s long-term

commitment to the region.

The remarks came during a re-

cent Russia-USA Business Forum

in Moscow, which took place at

the same time President Obama

was meeting with Russian presi-

dent Dmitry Medvedev.

“We share the vision that Rus-

sia can make a signifi cant and sus-

tainable contribution to help meet

the world’s growing demand for

food, energy and forest products,”

says Deere CEO Samual Allen.

“John Deere is working to expand

its Russian manufacturing capac-

ity for agricultural equipment by

early 2010. Ultimately, with the

support of the government of the

Russian Federation, Deere could

envision a series of signifi cant

investments over the next fi ve to

seven years in expanded capacity

for manufacturing and supporting

all types of Deere equipment.”

EFD Inc. Wins Solar Award

EAST PROVIDENCE, RI—

Dispensing equipment manufac-

turer EFD Inc., a subsidiary of

Nordson Corp., has won the 2009

International Solar Cell Award for

best technical product.

Presented at the 2009 InterSolar

Exhibition in Munich, Germany, the

award comes in recognition of the

company’s new PV cell ribbon and

bus bar attachment methodology: a

point-to-point soldering process that

uses a lead-free solder paste and

fl ux mixture to attach string ribbon

material to silver bus bars during so-

lar module assembly.

In addition to eliminating the

need for precoating with a liquid

fl ux, the process creates a robust

solder joint with minimal micro-

crack formation. The result is an

increased lifespan for the solar

modules in which it is used.

Kyzen Opening Malaysia Offi ce

NASHVILLE—Electronics

cleaning products manufacturer

Kyzen is opening a new sales and

support facility in Penang, Malay-

sia, as part of an ongoing effort

to increase the company’s market

share in the Asia-Pacifi c region.

“The possibility of a Kyzen fa-

cility in Southeast Asia has been

under consideration for some

time,” says Kyzen vice president

Tom Forsythe. “Malaysia is an im-

portant hub for high value-added

electronics and other high-tech-

nology manufacturing with a busi-

ness friendly environment and,

most importantly, with a highly

educated, dedicated work force.”

Founded in 1990, Kyzen pro-

vides cleaning products to a wide

range of customers, including those

in the electronics, metal fi nishing,

medical device, semiconductor and

optical components industries.

Volvo Kicks Off Fuel Cell Initiative

GOTEBORG, Sweden—Volvo

Group Launches Wind Energy Database

CLEVELAND—The Great Lakes WIND Network, an interna-

tional wind energy supply chain advisory group, has launched a new

web-based WIND Energy Supply Chain Database and Mapping

System, available online at http://maps.glwn.org/wind/, to promote

the growth of the wind power industry.

The site features an interactive map and a searchable wind supply

chain database containing the profi les of more than 1,000 manufac-

turers and organizations in the United States, Canada and Mexico

that actively serve the emerging wind industry.

Designed to facilitate customer-supplier relationships, the sys-

tem quickly connects manufacturers and suppliers with OEMs,

economic development offi cials, consultants and other wind power

supply-chain partners.

“The wind energy sector is the fastest growing industry in North

America. By linking buyers, sellers and other industry partners, we

believe this system can be a catalyst for business expansion, invest-

ment and new jobs,” says network director Ed Weston. “We are very

excited at the prospect of being able to service our global network

with a single site that supports supply chain needs.”

Access to the site is free. To register with the database, visit

www.glwn.org, select “Get Listed,” and complete a Wind Capabili-

ties Profi le to start the registration process.

Assembly Lines

Forecasts Mergers New facilities

Inventions


The Great Lakes WIND Network has created an online database to help wind energy companies locate suppliers and other renewable energy organizations.


group is teaming up with Midroc

New Technology, the OCAS re-

search center in Belgium and the

Swedish Energy Agency to devel-

op and produce a new generation

of fuel cells for possible use in ev-

erything from trucks to boats.

As part of the initiative, the three

members are forming a new joint-

venture company called Powercell

Sweden AB, based in Gothenburg,

Sweden. The $25 million effort is

expected to create some 100 new

jobs over the next three years.

Interior Components Company Expanding in Midwest

VALPARAISO, IN—UGN Inc.,

a manufacturer of interior trim

products for the automotive indus-

try, will invest about $3 million to

expand its production capacity in

northern Indiana. The company

says it will also add another 100

employees to its payroll by 2014.

“UGN continues to grow and

celebrate successes in a very chal-

lenging economic environment,”

says company CEO Randy Khalaf.

“Our Valparaiso facility is seeing

incredible expansion and is well

positioned with new products and

technology to see further growth

once the global economy starts to

show signs of recovery.”

Founded in 1986, the company

is adding 10,000 square feet of

manufacturing space to accommo-

date a new contract to produce in-

terior components for both luxury

automobiles and SUVs. The com-

pany also provides components

for small trucks.

Power Tool Demand Rising

CLEVELAND—Despite the

current recession, global demand

for power tools is expected to in-

crease 7 percent annually through

2013, according to a recent study

by The Freedonia Group.

Total annual demand is expect-

ed to be about $29 billion by the

end of the study period. The U.S.

market will continue to be the

strongest, accounting for slightly

over a third of total demand.

In addition to responding to an

eventual turnaround of the current

housing crisis, the U.S. market is also

expected to benefi t from the introduc-

tion of new and improved products,

such as cordless electric tools.

Freedonia researchers say there

will also be healthy demand in

Brazil, Russia, India and China,

with demand in China and India

rising about 6 percent annually in

the course of the study period.

For more on the study, visit

www.freedoniagroup.com.

Nordic Windpower Secures DOE Loan

BERKELEY, CA—The U.S.

Department of Energy has ap-

proved a $16 million loan to help

Nordic Windpower USA Inc.

expand its production facility in

Pocatello, ID.

The loan is being supported

through the 2009 American Re-

covery and Reinvestment Act,

signed into law by President

Obama in February.

Nordic Windpower manufac-

tures two-bladed, utility-scale wind

turbines featuring a fl exible “teeter-

hub” that helps dissipate the force

of turbulent winds that would oth-

erwise cause undue wear on the

system’s drive train. As part of the

expansion, Nordic plans to add an-

other 75 employees to its payroll.

“Nordic’s expansion will create

new and skilled green jobs to boost

the economy and help meet America’s

growing energy needs with clean

wind power,” says Tom Carbone,

CEO of Nordic Windpower. “We

appreciate DOE’s vote of confi dence

in our innovative technology and our

business model.”

Stäubli, Rixan Associates Joining Forces

DUNCAN, SC—Robotics

manufacturer Stäubli Robotics

is teaming up with the engi-

neering and integration compa-

ny Rixan Associates Inc. to co-

ordinate activities in the areas

of marketing and sales, with

an emphasis on robotic auto-

mation services, engineering

services, components, software

and training.

“We are building the future by

bringing two world-class orga-

nizations together in forming a

strategic partnership. This part-

nership will reinforce our mutual

customer-centric commitment in

providing fi rst class service and

support to our customers,” says

Stäubli Robotics division manager

Joe Gemma.

“We are excited about this new

partnership,” says Rixan President

Stephen Harris. “Rixan needed ro-

bots with higher payloads, faster

cycle times and robots that had

more application-specifi c features.

Stäubli robots fulfi ll those needs

and will provide our customers

with leading-edge technology,

high reliability and a worldwide

support network.”

Assembly Event Records Strong Attendance

NEW YORK—Despite a chal-

lenging economy, Canon Com-

munications says attendance was

up 3 percent at its recent assembly

and medical device trade event in

New York.

In all, some 24,000 buyers

were on hand for the co-located

MD&M East, EastPack, Automa-

tion Technology Expo East, Green

Manufacturing Expo and Atlantic

Design & Manufacturing shows

held at the Javits Convention Cen-

ter in June.

“A number of our exhibitors

expected that attendance would

be down because of the current

state of the economy,” says Canon

Communications CEO Charles G.

McCurdy. “Instead, the success of

this event has generated consider-

able optimism among them about

the enduring business vitality of

key advanced manufacturing seg-

ments, most notably medical de-

vices.”

As further evidence of this fact,

McCurdy says about two-thirds of

the event’s 1,000 exhibitors have

already contracted for space in the

2010 show.

“The MD&M East Show al-

lowed us to land more than 90

leads, of which 75 percent or more

have immediate needs for our

products and services,” says Ken

Jenkins, president of Ohio-based

mold maker Pleasant Precision

Inc. “I have displayed at more

than 15 trade shows in the past

10 years, and the MD&M East

Show provided more substantial

leads than all of the other shows

together.”

For more on Canon Commu-

nications, which also organizes

the Assembly Technology Expo

in Rosemont, IL, sponsored by

ASSEMBLY magazine, visit

www.cancom.com.

Canon Communications’ trade show in New York continues to grow, despite the tough economic climate.

Assembly in Action


Comau Group, a subsidiary of

Fiat Spa, builds automated

production machines for a

wide range of customers, in-

cluding those in the automo-

tive industry. The company

also manufactures turnkey automated

assembly systems, robots, weld guns,

conveyors, recognition software and

other automation components.

Recently, engineers at the company’s

North American headquarters in South-

fi eld, MI, developed what they call

VersaVision II software as an upgrade

to the company’s

existing robotic

guidance systems.

The new software

allows a robot to

both pick up parts

and then position

them in space us-

ing a single ma-

chine-vision cam-

era, as opposed to

multiple cameras.

The software can

be used with any

GigE camera or

robot currently on

the market. By re-

ducing the number of cameras, the sys-

tem helps assemblers reduce costs.

“The VersaVision II program pro-

vides our robots true visual recogni-

tion,” says Comau product develop-

ment engineer Max Falcone. “The

software emulates the visual cortex of

the human brain, teaching the system

to recognize an object the same way

you would teach an infant. We show

the system an object by taking a picture

of the object and naming it. All of the

information pertaining to that object is

stored into the system’s memory, which

allows the system to recognize the tar-

get part and maneuver a servo-actuated

manipulator to pick, place or work on

that object.”

To make the system as effective and

effi cient as possible, Comau engineers

wanted to reduce the amount of cabling

connecting the robot-mounted camera

to the robot controller. Standard GigE

cameras require three cables: one for

communications, one for power and

one to trigger the camera to take a pic-

ture. Three cables means three times

the opportunity for failure in a single

camera application.

“To make our robotic guidance sys-

tems as reliable and cost-effective as

possible, we wanted to take our de-

sign one step further,” says Comau

robotics and vision products manager

Tony Ventura. “Not only did we need

to reduce the number of cameras in

our systems, we wanted to reduce the

chances of system failure associated

with cabling. The more cables located

on a robot, the higher the risk of cable

failure.”

To solve the problem, Comau in-

corporated a TXG camera with power

over GigE cabling from Baumer Ltd.,

a manufacturer of sensors, motion-

control equipment and machine vision.

In the Comau application, the camera

includes a specially developed indus-

trial power injector module or Ethernet

By eliminating the need for any additional cables, the camera minimizes the risk of cable fatigue and greatly improves the integrity of the vision system.

Single-Cable Camera Maximizes Effi ciency

Comau engineers wanted to reduce

the amount of cabling connecting

the robot-mounted camera to the

robot controller.

For reprints of any Assembly in Action article, please contact Cindy Williams at [email protected] or 610-436-4220 ext. 8516.

switch that provides power down a Cat6

Ethernet cable at distances up to 100

meters. By eliminating the need for any

additional cables, the Power over GigE

Camera minimizes the risk of cable fa-

tigue and greatly improves the integrity

of a vision system.

According to Falcone, Comau also

liked the camera because of its robust

design and performance features. “The

camera is neat, complete and well engi-

neered. The lock-style connections are

strong, reliable, industrially accepted

M8 connectors. The integrated UV

fi lter mounted in front of the camera’s

face eliminates the need to buy and in-

stall a separate fi lter to show true col-

ors. This high-quality camera allows us

to provide our customers with an over-

all lower cost system,” he says.

For more on machine vision, visit

www.baumerelectric.com/usa or call

800-937-9336.

For more on automation, call 248-

353-8888 or visit www.comauinc.com.

Vision Enables Feeder to Handle Multiple Parts

Traditional vibratory bowl feeders use

a helical shelf-like inclined ramp

winding up from the bottom of a bowl

to a discharge passageway. The pas-

sageway’s reciprocating motion pushes

the parts up the ramp. Obstructions,

cutouts and other orienting devices are

arranged along the passageway to topple

off parts that are incorrectly

oriented and allow through

only those parts that are po-

sitioned correctly.

Historically, because of

the various hard-tooled

orientation features that

are required, this kind of

equipment has been very

part-specifi c. However, the

robotics company Rixan

Associates Inc. has devel-

oped a new fl exible vibrato-

ry bowl feeder that includes

a robot and machine vision

system to orient multiple

parts using a single system.

Rixan originally developed the

system to load dozens of different

aerospace fasteners into a press, a

task that was previously

performed by hand and

would have otherwise

required installing many

different feeders to

automate.

The new system em-

ploys a vibratory bowl

feeder that randomly pres-

ents the parts to the vision

system, which in turn,

stops the feeder when it

sees the correct part in

the correct orientation so

that a robot can load the

part into the press. The

parts are presented on a

semitransparent, backlit

plenum, so the vision sys-

tem can easily identify them. The parts

that are not picked automatically recycle

into the bowl. The result has been a 20

percent increase in productivity and one

less operator to tend the press.

Critical to the success of the system

has been its In-Sight 5401 vision sys-

tem from machine vision manufacturer

Cognex Corp., which is integrated with

an RV-6SL-S11 robot and Melfa-Vision

software from Mitsubishi Electric.

Rixan chose the In-Sight 5401 because

of its processing power and the fact that

it can acquire up to 60 complete eight-

bit images per second.

To develop the application, Rixan

engineers fi rst used the Melfa-Vision

software to calibrate the robot in rela-

tion to the feeder. They then put a part

in the robot gripper and “jogged” the

robot over to the feeder where it set the

part down on the plenum. In this way

engineers “taught” the robot to pick up

the part in this orientation and at this

point on the plenum.

Once the robot had been taught how

to pick up the part, Rixan’s engineers

used the Cognex camera’s PatFind

object-location tool to draw a rectangle

around the part on the screen, thereby

allowing the vision system to automati-

cally recognize the part as it moves

across the plenum.

In operation, when it sees a part, the

system fi rst sends a signal to stop the

feeder. After the feeder has stopped, the

vision system acquires one last image to

determine the exact position of the part

and calculate its angle of presentation.

The robot then moves to the location

of the part, twists its wrist to match the

part’s orientation, picks up the part and

sends a signal to restart the feeder.

Most of the parts in the aerospace

fastener application are symmetrical

top to bottom so they can be identifi ed

from their silhouette alone. However,

in those instances where a part has two

distinct sides, the Cognex PatMax tool

can be used to recognize which side is


The new software allows a robot to both pick up parts and position them in space using a single camera.

The system employs a vibratory bowl feeder that randomly presents the parts to the vision system, which in turn, stops the feeder when it sees the correct part in the correct orientation.

Assembly in Action

up. Top-down lighting is used

for parts in which pattern

recognition is required. White

light is used for some parts,

while glare-free polarized

lighting is used for others.

“A key to the success of

this application is the ease-of-

setup, accuracy and reliability

of the Cognex In-Sight vision

sensors,” says Rixan Associ-

ates President Stephen Har-

ris. “The PatMax tool that we

use to recognize part features

is much faster and more ac-

curate than other comparable

industry tools that we have

seen. The easy integration be-

tween Cognex vision sensors

and Mitsubishi robots drasti-

cally reduces the amount of

time required to develop vision-enabled

robot applications and in most cases

eliminates the need for writing a single

line of code.”

For more on machine vision, call 508-

650-3000 or visit www.cognex.com.

For more on parts feeding and

automation, call 937-438-3005 or visit

www.rixan.com.

Screen Printer Adapts to Changing Needs

DCI Inc., in Olathe, KS, designs and

manufactures electronics compo-

nents and subassemblies for custom-

ers in a wide range of industries. The

company specializes in the design and

manufacture of specialized custom liq-

uid crystal displays, light emitting di-

ode displays and operator interfaces.

Recently, the company expanded its

electronics manufacturing capacity by

implementing a new Horizon 03i fully

automatic screen-printing system from

electronics assembly equipment manu-

facturer DEK USA Inc.

According to DCI chief operating

offi cer Mike Morgan, the company

went with the Horizon 03i because of

its high print quality and ease of use.

Morgan says his company also likes the

system’s quick setup and changeover

times, as well as its new HawkEye print

verifi cation inspection feature.

“We evaluated several screen printing

systems,” Morgan says. “The capability

of DEK’s Horizon 03i coupled with

the staff’s depth of knowledge and

process expertise made our decision an

easy one. With the Horizon platform’s

new scalability, future-proofi ng and

ability to customize, we can modify

the system to meet our manufacturing

requirements as our business changes

and grows.”

DEK’s entire

Horizon line of

screen printers

includes mo-

torized sten-

cil alignment,

fast product

changeover, 2.0

Cpk print pro-

cess capability

and Six Sigma

production per-

formance. The

system’s In-

stinctiv V9 user

interface allows

manufacturers

to seamlessly in-

tegrate advanced

options like speed enhance-

ment, next-generation un-

derstencil cleaning technol-

ogy and automatic board

support, as required.

“It’s no coincidence that

DCI has been named to

Fortune Small Business magazine’s list of the fastest

growing small companies

for the past two consecu-

tive years,” says DCIs vice-

president of business devel-

opment Jay Gillam. “When

your top priority is ensur-

ing your customers receive

outstanding service and su-

perior quality products on

time every time, business

success is inevitable. Our

addition of DEK’s Horizon

03i is just one more example of this

commitment.”

For more on custom electronics man-

ufacturing, call 888-824-9412 or visit

www.dciincorporated.com.

For more on screen printing systems,

visit www.dek.com.

Workbenches Harmonize With Design Goals

One of the goals of the school of

architecture at the University of


The screen printer’s scalability means it can be modified to meet DCI Inc.’s future manufacturing needs as well as those in the present.

When the school of architecture at the University of North Carolina went shopping for new workbenches, it ended up going with a set of stations from industrial workstation manufacturer Lista International.

North Carolina in Charlotte is to

help students “apply strategic think-

ing to environmental problems.” It

was therefore only natural that when

the school needed a new set of work

desks, the students should take part

in the selection process.

“Our existing desks had worn out

their welcome,” says Ken Lambla,

dean of the university’s college of

arts and architecture. “The old desks

were custom-designed and custom-

made when we first occupied our

building in 1991. They may have

been sufficient then, but today they

didn’t offer the kind of flexibility the

students’ work demanded. Not only

were the dimensions and ergonomics

insufficient, but they were lacking in

many key areas of functionality: no

power supplies, no wheels for mobil-

ity, inadequate display surface, and

serious storage limitations.”

Ultimately, after consulting with a

student-run focus group and putting

the project out for bid, the college

replaced more than 200 of its old

desks with a set of Arlink worksta-

tions from industrial workbench and

cabinet manufacturer Lista Interna-

tional Corp.

According to Rich Preiss, the school’s

director of laboratories, the school

chose the Arlink workbenches because

they were rugged, functional and aes-

thetically pleasing.

Lambla adds that Lista was also very

responsive in terms of meeting the

school’s particular needs.

“Being architects, we’re pretty

detail driven,” he says. “We needed

a company that was going to work

with us on the exact details of fabri-

cation as it relates to the experience

we’ve had over the last 15 years.

Lista brought a lot of knowledge to

the table and demonstrated an ability

to create custom application-specific

solutions.”

Lambla adds that the company was

able to work within a narrow time

frame, another reason the college went

with the Arlink desks.

“We needed somebody who could

supply these workbenches within a

very tight window of time—about

eight weeks to be exact. This

included about one week for delivery

and installation,” he says. “At the

university level, we call the money

that’s left over from the annual

budget ‘one-time money.’ This is

what we were working with, and if

we didn’t use it by the given deadline,

we’d lose it. Fortunately Lista came

through, not only on time, but with

completely assembled products.

Many of the other bidders were

delivering only parts. Lista provided

a ready-to-use solution.”

For more on workstations, call 800-

722-3020 or visit www.listaintl.com.

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As most people age, they become

wiser. But, gradual vision loss

is something that even the

smartest people in the world

can’t avoid. That simple fact

of life is good news for the

ophthalmic device industry.

Cataracts, glaucoma, macular degen-

eration, presbyopia, diabetic retinopa-

thy, posterior uveitis and other vision-

related conditions make ophthalmology

one of the most dynamic market seg-

ments in the medical device industry.

An aging population, proposed fed-

eral healthcare reform and an increas-

ing number of elective surgeries, such

as Lasik treatment, is creating a huge

demand for diagnostic instruments, sur-

gical equipment, lasers, intraocular lens

implants, shunts, artificial retinas and

other products.

Approximately 50 percent of

all adults in the United States don’t

have 20/20 vision, because they are

nearsighted, farsighted or have an

astigmatism, which is an irregular curve

of the cornea. By 2020, the number of

people who are blind or have low vision

is projected to increase dramatically.

“Blindness or low vision affects 3.3

million Americans age 40 or over . . . and

this figure [will] reach 5.5 million by the

year 2020,” says Elias Zerhouni, M.D.,

director of the National Institutes of

Health (Bethesda, MD), which operates

the Eye Disease Prevalence Research

Group and the National Eye Institute.

“As our population lives longer, eye

disease will be an ever greater concern.

Low vision and blindness increase

significantly with age, particularly in

people over age 65.”

A recent study conducted by RTI

International (Research Triangle Park,

NC) and the Centers for Disease Control

and Prevention (Atlanta) predicts there

will be a huge demand for ophthalmic

devices over the next four decades.

“The aging U.S. population will lead to

a large increase in early and advanced

age-related macular degeneration,”

claims David Rein, a senior research

economist at RTI.

“By 2050, the number of people with

early age-related macular degeneration

will double to more than 17.8 million,”

Rein points out. At the same time, he

expects the number of cases of diabetic

retinopathy, which is the leading cause

of blindness among working-age adults

in the United States, to increase from

5.5 million to 16 million.

Better One or Better Two?

ASSEMBLY Medical Device Assembly

Ophthalmic device manufacturers keep an eye on new technology.

� By Austin WeberSenior Editor


Because of the aging population, there will be a huge demand for ophthalmic devices over the next four decades. Photo courtesy Carl Zeiss

Meditec AG


“The good news is that medical

technologies are changing rapidly,”

says Rein. “Ten years ago, there were

no treatments for age-related macular

degeneration. With luck, tomorrow’s

discoveries will lead to far greater

reductions in visual impairment and

blindness.”

According to MedMarket Diligence

LLC (Foothill Ranch, CA), the

worldwide ophthalmic products market

exceeds $22 billion and is growing at

more than 10 percent annually. The

industry is dominated by several

major players, such as Abbott Medical

Optics Inc. (Santa Ana, CA), Alcon

Laboratories Inc. (Fort Worth, TX),

Bausch & Lomb Inc. (Rochester, NY)

and Carl Zeiss Meditec AG (Jena,

Germany). However, numerous small

start-up companies specialize in niche

segments, such as cataract, corneal or

refractive surgery.

No matter the size of the company,

ophthalmic manufacturers are focusing

their efforts on making surgical proce-

dures faster, easier, more accurate and

more affordable. There’s also a growing

trend toward drug-device combination

products.

Diagnostic Tools

Traditionally, the ophthalmic indus-

try is divided into two main segments:

diagnostic instruments and surgical

devices. Diagnostic instruments are

used by ophthalmologists to examine

their patients. They include refractors

(the “better-one, better-two” device

that’s used in conjunction with an eye

chart), slit lamps (an upright micro-

scope equipped with a bright light) and

tonometers (a device that measures eye

pressure).

Ophthalmologists are always

looking for equipment that makes them

better clinicians. They want instruments

that provide information that allows

them to make better diagnoses and

more efficient treatment decisions in a

patient-friendly manner.

“The latest trend is toward non-

invasive diagnostic imaging,” says

Andrew Shatz, M.D., an ophthalmol-

ogist at the Woolfson Eye Institute

(Atlanta). “High-speed ultrasound

and scanning laser tomography are

both giving increasingly sharper reso-

lution of the microscopic structures of

the eye, allowing for a more detailed

view of pathology.

“This has also allowed us to

visualize the relationship between the

different regions of the eye in a way

we have never been able to before,

without having to resort to intravenous

dye injection,” explains Shatz. “More

doctors are adopting technology that

allows us to image the back of the eye

without the need for dilation.”

“We now have incredibly precise

imaging devices called OCT (optical

coherence tomography) that allow us to

create microscopic images of structures

inside the eye that were never before

visible,” adds John Hovanesian, M.D.,

an ophthalmologist at Harvard Eye

Associates (Laguna Hills, CA) and

a clinical instructor at UCLA’s Jules

Stein Eye Institute (Los Angeles). “This

greatly aids in diagnosis of conditions

like diabetic eye problems, eye tumors

and macular degeneration.”

An OCT allows an ophthalmologist

to construct three-dimensional images

of living eye tissue with better resolution

A wide variety of diagnostic instruments are used by ophthalmologists to examine patients, such as slit lamps. Photo courtesy National Eye Institute

The human eye is a complex, delicate organ. Common back-of-the-eye diseases include age-related macular degeneration and glaucoma. Illustration courtesy American

Academy of Ophthalmology

than a traditional MRI scan.

Better yet, the procedure

can be performed in a

doctor’s office instead of a

hospital.

Today’s new breed of

diagnostic instruments use

state-of-the-art technology

to objectively measure and

quantify vision disorders.

For instance, engineers at

Optos Inc. (Marlborough,

MA) recently developed

a new type of imaging

device that provides an

ultra-widefield view

of the retina. It allows

ophthalmologists to see

more than 80 percent of

the retina, compared to a

traditional camera that provides a much

narrower view—about 11 percent. The

device uses scanning coherent laser

light rather than full spectrum white

light that’s typically used by cameras

and other forms of ophthalmoscopy.

Researchers at the National Eye Insti-

tute (Bethesda, MD) and the National

Aeronautics and Space Administration

(NASA, Washington, DC) recently

adapted a compact fiber-optic probe

developed for the space program into

the world’s first noninva-

sive early detection device

for cataracts, the leading

cause of vision loss world-

wide. The new device is

based on a laser light tech-

nique called dynamic light

scattering (DLS).

It was initially devel-

oped to analyze the

growth of protein crystals

in a zero-gravity space

environment. The table-

top DLS device is used

to detect the earliest dam-

age to lens proteins, trig-

gering an early warning

for cataract formation and

blindness.

“Much of the work [in

the diagnostic instrument field] is going

into finding ways to treat presbyopia to

enable people to get rid of their reading

glasses,” says James Ohneck, CEO of

Oculatek Inc. (Cleveland). The start-up

company has developed a transscleral


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This telescopic implant is 4 millimeters long and contains two wide-angle glass lenses. It is designed to treat age-related macular degeneration. Photo courtesy

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light therapy system that uses a low

level of infrared light at a specific wave-

length. “It helps strengthen the ciliary

muscle, which weakens as the eye ages

and is one of the factors that leads to

the eye’s inability to accommodate,”

Ohneck points out.

“It is therapy, not surgery,” adds

Ohneck. “The patient has several short

therapy sessions where they look into

a binocular while the eye is dosed

with infrared light. The treatment does

not harm the eye and there is no pain

associated with the procedure. It’s unique

because it is the first device of its kind to

therapeutically treat presbyopia without

an invasive surgical procedure. Newer

technologies being developed involve

implanting special lenses through a

surgical procedure or modifying the

shape of the eye to adjust vision.”

Even noninvasive ophthalmic pro-

cedures must be cleared by the U.S.

Food and Drug Administration (FDA,

Washington, DC), which often hinders

start-up manufacturers and prevents

them from quickly ramping up produc-

tion. For instance, Oculatek’s device is

still undergoing trials with the FDA. If

approved, it won’t be readily available

to ophthalmologists for several more

years.

“The challenges around new devices

are regulatory in nature, such as

getting FDA approval and validating

the efficacy through clinical trials,”

says Ohneck, who holds a degree in

electronic engineering. “This takes time

and money. Investors are reluctant to

put money into products that don’t have

the trials, so it’s a chicken and egg;

you need money to do clinicals, but

you can’t get it until the clinicals are

completed.”

To reduce costs, many start-up

manufacturers outsource assembly to

third parties. For instance, Oculatek is

working with Valtronic Technologies

Inc. (Solon, OH). That allows Ohneck

and his colleagues to focus their

attention on product development.

Ophthalmic devices are typically

assembled in clean rooms. Large

manufacturers, such as Alcon, have

recently been focusing their efforts on

ergonomics and automation. Alcon’s Fort

Worth plant recently celebrated its 50

anniversary, and the company is currently

building a new facility in Singapore to

supply the fast-growing Asian market.

“In our more manual assembly areas,

we have invested in adjustable work-

stations and eliminated microscopes

to make our operators more comfort-

able,” says Melissa Mota, a company

spokesperson. “In addition, we have

invested heavily to automate mid- and

higher-volume operations and products.

Our focus has been on advancing our

assembly processes to be flexible with

high-mix automation, in order to satisfy

increasing demand for our products.”

Implantable Devices

One of newest technological advanc-

es on the surgical side of the ophthalmic

device industry is the correction of pres-

byopia, which affects 90 million people

www.assemblymag.com August 2009 / ASSEMBLY 25 asb08094dymax.indd 1 7/14/09 10:20:55 AM


in the United States, with multifocal

and accommodating implants. “These

not only improve distance vision with-

out glasses, but also decrease the need

for readers,” says Shatz. “This market

has been heating up over the last few

years. What has started out with three

competing lens models will [eventu-

ally] blossom to 10 or more different

technologies, all aimed at achieving the

holy grail of ophthalmology.

“The new revolution is almost at

hand,” claims Shatz. “Improved lens and

cataract surgery technology, in combi-

nation with the baby-boomer generation

now developing cataracts, has created

the perfect breeding ground for pres-

byopic lens implants. This technology

will overtake laser vision correction as

the primary means of correcting vision

in the next five to 10 years.”

Intraocular lenses (IOLs) are

typically made of either acrylic or

silicone. Early versions were made of an

acrylic polymer called PMMA, which is

what led to the discovery of using IOLs

in cataract surgery.



An OCT allows ophthalmologists to construct three-dimensional images of living eye tissue with better resolution than a traditional MRI scan. Photo courtesy Carl Zeiss Meditec AG

This fiber-optic probe uses NASA-developed technology to detect cataracts. Photo courtesy National Eye Institute

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The latest trend in IOLs is

toward corrective, foldable lenses

that are structurally designed to

minimize secondary cataracts from

occurring. Most companies developing

intraocular implants are focusing their

efforts on devices that treat back-of-

the-eye diseases, such as glaucoma and

acute macular degeneration.

For instance, Alcon recently

unveiled the third generation of its

Restor lens. The multi-focal device

contains 12 concentric “steps” around

the optic zone of the lens, which appear

as rings. They create different focusing

levels from near to distant vision. The

surgical procedure is painless and

only takes about 20 minutes. Some

ophthalmologists are recommending

the procedure as an alternative to the

more controversial Lasik treatment.

In addition, engineers and doctors

are currently developing polymeric

drug delivery devices that are implanted

at the time of cataract surgery along

with an IOL. The hybrid devices are

designed to treat the most common

postoperative complications, such as

inflammation, infection and secondary

cataracts.

“Drug therapy ease of use is of

considerable importance as the world’s

population continues to age,” says Tracy

Klein, CEO of Inson Medical Systems

Inc. (Bellevue, WA). “There is a

considerable opportunity to reformulate

older pharmaceuticals into implantable

devices. Eye drops are the standard of

care for most ophthalmic diseases, yet

they have poor penetration into the eye

and are inconvenient for patients to

administer, often with four to six times

per day dosing.”

Klein’s company is developing front-

of-the-eye drug delivery beads that are

smaller than a grain of rice. “We plan to

utilize this expertise on future products


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This instrument is used for cataract surgery. It features a high-definition touchscreen display and Bluetooth wireless technology. Improved fluidics enhance cutting efficiency, speed and accuracy when making smaller, noninvasive incisions. Photo courtesy Bausch & Lomb Inc.


Capital Spending

for back-of-the-eye applications,” he

explains. “We are also in very early

development discussions with potential

partners who are interested in utilizing

our technology to create IOLs capable

of drug delivery.”

Implantable intraocular lenses pose

numerous manufacturing challenges.

“The main challenge for us is to make a

device small enough to be inserted with

the lens, yet big enough to hold enough

drug,” says Klein. “There are also

technical challenges to overcome with

existing injection molding techniques

when making devices this small.”

For instance, lenses must be extreme-

ly thin to be flexible and comfortable to

patients. Klein believes the ophthalmic

device industry may be able to adapt

existing semiconductor manufacturing

technology and equipment if devices

get smaller.

“[However], ophthalmic implantable

devices must be as long-acting as

possible for obvious reasons,” says

Klein. “Therefore, they are unlikely to

get much smaller. In addition, surgeons

generally want devices they can retrieve

if necessary.”

“The goal at the moment is to achieve

better efficacy with less invasive proce-

dures,” notes Paul Ashton, M.D., presi-

dent of pSivida Corp. (Watertown, MA).

“There are a lot of blinding diseases

for which there are no drug treatments

yet approved. These diseases include

dry age-related macular degeneration

(AMD) and diabetic retinopathy.

“Recently, there have been some

drug treatments approved for wet-form

AMD, but this typically consists of an

injection into the eye every couple of

months,” Ashton points out. “A [more]

effective and less invasive treatment

for this disease [would] be quite an

advantage.”

Ashton and his colleagues

have recently developed a variety

of ophthalmic devices for either

implantation or injection into the eye.

The devices are made from a proprietary

porous silicon material.

Vitrasert was the first sustained

release device approved for back-of-

the-eye applications. It’s about the size

of a pepper corn (6 millimeters long

and 2.5 millimeters wide). The device is

surgically implanted into the eye, where

it releases drugs for six to eight months.

“Because the drug is released directly

into the eye, it requires approximately

20,000 times less drug than would be

needed if given intravenously,” says

Ashton.

Retisert is a smaller device that is

5.25 millimeters long and 1.5 millime-

ters wide, or about the size of a grain of

rice. It lasts 2.5 years after implantation

into the eye. “As it releases its drug

directly into the eye, it delivers about

200,000 times less drug than would

be needed if the patient took the drug

orally,” claims Ashton. It is the only

FDA-approved treatment for posterior

uveitis, a potentially blinding disease.

“Implanting either Vitrasert or Retisert



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Ophthalmic devices, such as intraocular lenses, are typically assembled in clean rooms. Photo courtesy Carl Zeiss Meditec AG


is a little like having a cataract opera-

tion,” says Ashton.

The next step in the evolution of this

series of implantable devices is called

Iluvien. The device is much smaller

than Retisert (only 3 millimeters long

and 0.5 millimeter wide), but it’s

designed to last about the same length

of time. “It’s about the length of an

eyelash and is small enough to fit into

a needle,” says Ashton. “This allows it

to be injected directly into the eye in

an office visit [as opposed to outpatient

surgery, with fewer complications]. The

procedure is also far cheaper.”

According to Ashton, future

ophthalmic devices will continue to

get smaller and more sophisticated.

“Bioerodible systems are already in early

stages of testing,” he points out. “Applying

existing semiconductor [manufacturing

processes] and nanotechnology [will

create] ‘intelligent’ devices that respond

to a disease or tell a physician if they are

about to run out [of a drug].”

In addition to improved lens implants

and drug-device hybrids, another new

device that intrigues many ophthal-

mologists is the artificial retina. “This

device has given hope to patients who

have lost vision from disabling retinal

diseases such as macular degeneration,”

says Shatz. “While the resolution is

currently only able to allow for ambula-

tory vision, higher resolution electrode

arrays under development will be able

to differentiate letters and objects.”

The artificial retina, called Argus II,

is being developed by engineers at Oak

Ridge National Laboratory (Oak Ridge,

TN) and the University of Southern

California (Los Angeles). It consists

of an array of 60 electrodes that are

attached to the retina. The electrodes

conduct information acquired from an

external camera to the retina to pro-

vide a rudimentary form of sight. The

device has already been implanted in

six patients. A newer, higher resolution

model will be available within the next

few years. A



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Tag Marking

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Manufacturers mark parts

for many reasons: to

differentiate between

similar-looking parts; to

indicate that a process

has been performed or

a quality check has been passed; to

facilitate assembly; or to link a product

or component to the assembly line or

machine on which it was produced.

Parts like calibration screws may even

be marked with stains that only become

visible under ultraviolet light to indicate

whether they have

been tampered with.

One of the most

common uses of color

marking is to make

it easier to tell the

difference between

parts that look similar.

Although such parts

may be marked

w i t h n u m b e r s ,

letters or some other

ident i fier, some

companies choose

to color-code them

as well, to speed and

simplify identification on the shop

floor. For example, two springs may

appear identical, but may function very

differently. Marking each one with a

different color stripe is a simple way to

tell them apart.

Another major use for parts marking

systems is in quality control. Parts

are often marked after a test has been

performed to indicate whether they have

passed or failed. Parts are also marked

to indicate that a particular process

has been completed. This is especially

useful if that process does not visibly

change the parts.

Marking systems are often integrated

into testing or production fixtures. An

example is a flywheel that gets mounted

on an engine with multiple bolts, which

are then simultaneously tightened.

When all of the bolts have been torqued

to specification, the marking device

moves into position and applies a dot

to confirm that the operation was per-

formed correctly. If the dot is not there,

operators downstream will immediately

know that additional inspection or cor-

rective action is required.

Parts are also frequently marked with

color to facilitate assembly processes.

For example, assemblers may put a dot

of stain on brake calipers to confirm

that pads have been installed before

mounting rims and tires. Or, a shaft

could be marked to indicate which end

to insert.

Marking is also used in automotive

and other stamping processes to check

the contours of stamped parts during

setup to indicate whether a bend has

the correct radius or a crease is straight.

In applications like this, color marking

provides an easy way to point out any

When All You

Need Is a Dot

ASSEMBLY Parts Marking

Marking parts with colored inks or stains is a fast, easy way to differentiate between similar-looking components, indicate pass-fail status or confirm that a specific process has been performed.

� By John KeatingBusiness Unit Manager, ITW DYKEMOlathe, KSandClaude BergeronProduct Line Manager, EFD Inc.East Providence, RI


Parts such as calibration screws can be marked with stains that only become visible under ultraviolet light to indicate whether they have been tampered with. Photo courtesy ITW DYKEM

Clogging can be

minimized by using

a low-volume, low-

pressure spray

system.


discrepancies so the operator

can fine-tune the press setup.

Three Marking Methods

Common part marking

methods include handheld

valve-actuated markers, contact

marking systems that press

a stain-saturated pad against

the part, and noncontact spray

marking systems.

The simplest of all marking

“systems” are handheld valve-

actuated markers, which are

often used in processes such as

filling an automatic transmission

with fluid and then marking the

dipstick for visual confirmation.

Contact marking systems

consist of an ink or stain reser-

voir fitted with a pad or dauber

and mounted on an air cylinder

or similar device. As the part

moves into position or the test

or process is completed, the

actuator advances to press the

saturated dauber against the part.

Depending on the marking fluid,

the parts may need to be clean

and dry to achieve an acceptable

mark.

Noncontact marking systems

typically use a pneumatic spray

valve to apply spots, stripes and

bands, with stain supplied from

a tank or disposable reservoir.

Depending on the application,

the valve can be mounted in a

fixed location or attached to an

actuator that moves it to the part.

In some processes, the part is

rotated while the valve applies

a band of color around the outer

circumference.

Pigment and Maintenance

Marking fluids are commonly

referred to as inks, staining colors

or paints, and generally fall

into one of two classifications:

transparent or opaque.

Transparent staining colors

have a thinner viscosity than

opaque stains and dry slightly

faster. They are typically used on

lighter colored substrates or in

marking applications involving

tight tolerances, such as engine

rods. Transparent stains will not

settle or separate.

Opaque stains use more

pigment to produce a heavier

mark, and perform well on both

light and dark substrates. These

stains apply slightly thicker

than transparent stains and take

slightly longer to dry. Thickness

can be adjusted by adding

thinner.

Because they contain more

pigment, opaque stains will

settle over time, and daubers will

need to be periodically agitated

to work properly. Opaque stains

also increase the likelihood of

spray nozzles clogging and

requiring maintenance.

Nozzle clogging is a common

problem with spray valves,

particularly when using heavily

pigmented, opaque paints and

stains. To avoid applying a

thick, heavy spray mark that

is slow to dry, valve stroke is

usually shortened to “choke

down” the aperture to reduce

coating thickness. This causes

the pigment to be filtered out of

suspension at the valve nozzle,

causing it to clog.

Clogging can be minimized

by using a low-volume, low-

pressure (LVLP) spray system

to apply the stain. Because

LVLP designs work with lower

pressures and flow rates than

standard spray systems, a longer

valve stroke can be used. This

leaves more space around the

valve needle, which reduces the

possibility of pigment building

up to the point where it eventually

blocks the valve nozzle.

Separation is another issue

with many pigmented stains.

This occurs when the pigment

separates from the carrier and

settles to the bottom of the

reservoir, resulting in fainter, less

consistent marks that may not be

picked up by visual scanning

systems.

This spray valve has a dual-ported fluid head. A programmable air delay after each shot keeps the nozzle clean and reduces clogging and maintenance. Photo courtesy EFD Inc.

This spray marking system uses a motorized gear pump to keep pigmented inks in suspension and constantly circulating through the valve. Illustration courtesy EFD Inc.

Both issues—clogging and

separation—can be prevented with

an LVLP spray marking system

with a double-ported fluid head and

a recirculating pump that keeps the

marking fluid moving so the pigment

remains in suspension.

EFD’s new 781RC recirculating

spray marking system is an example of

this type of equipment. A motor-driven

gear pump pulls fluid from the reservoir

and supplies it to the spray valve, where

it enters one side of the fluid head and

exits the other. As fluid is returned to the

reservoir, it produces a slight agitation

that keeps the pigment from settling

at the bottom of the tank. Because

as little as 1 psi is sufficient pressure

to keep the marking fluid constantly

recirculating, a long valve stroke can be

used to maintain open space around the

valve needle, while a programmable air

delay after each shot keeps the nozzle

clean and further reduces the risk of

clogging.

Choosing a Marking System

When comparing contact and

noncontact marking systems, engineers

should consider these factors:

marking speed. �

the cost of the marking fl uid and �

need to maintain inventory (individual

stain bottles and applicators vs. less

expensive bulk bottles).

the need to regularly monitor the �

system to ensure ink is in the bottle vs.

using a tank that can be fi lled once at

the start of a shift.

time needed to change ink bottles or �

refi ll a tank and whether the line must

be shut down to do this.

time and cost of replacing �

contaminated or dried out pads and

daubers.

Once maintenance requirements,

downtime, fluid costs and line speeds

have been considered, a noncontact spray

marking system often proves to be a more

economical long-term choice. A


ASSEMBLY ONLINEFor more information on parts marking, visit www.assemblymag.com to read these articles:� On Your Mark.� Rubber Stamping Assembly.� The Expanded Reach of Laser Marking.


Parts Marking

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A simple dot of color can differentiate between similar-looking parts; indicate that a quality check has been passed; or link a product to the assembly line or machine on which it was produced. Photo courtesy ITW DYKEM

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Selective soldering with a

miniature wave or fountain

of molten solder offers many

advantages compared with

conventional wave soldering

equipment. It requires less

energy, generates less dross, provides

more control, and can reach certain

joints that would otherwise be

inaccessible. Moreover, there’s no need

for custom-made pallets or shielding for

the boards.

These systems can be

equipped with a single

circular nozzle 2 to 20

millimeters in diameter,

a rectangular nozzle

4 to 8 inches long, or

multiple nozzles for

soldering more than one

joint simultaneously.

Molten solder is pumped

through the nozzle to

create a fountain with a

directional or spherical

shape.

In some systems, the

printed circuit board is

held stationary, and

the solder fountain moves beneath it

to solder pins, rows and connectors.

The fountain travels in three axes (X,

Y and Z) up to solder points and down

and around bottom-side components.

Precise motion control and the small

size of the wave prevent damage to

nearby components and pads.

Other systems hold the fountain

stationary and move the PCB. Often

referred to as “top-side gantry” systems,

these machines can position boards

along two additional axes of motion:

tilt and rotation.

These fourth and fifth axes enable

the solder wave to get around bottom-

side components and penetrate areas

that otherwise could not be reached by

a three-axis system. In addition, top-side

gantry systems can tilt boards for angled

soldering, which can improve yields.

Different Strokes: EMS Views

Change is a constant in electronics

assembly. New alloys, fluxes and

temperature demands are the norm.

Production volumes increase and

decrease quickly, and design life

cycles can be short. Floor space is at a

premium, and there is a constant push to

reduce costs, increase productivity and

improve quality. In this environment,

assemblers must run lean, green and

mean. This has opened up opportunities

for selective soldering technology.

Dave Sackett is a consulting

engineer in Maplewood, MN, who

has worked with many electronics

assemblers. He recommends selective

soldering systems driven by precision

servomotors, as opposed to inexpensive

stepper motors. Automatic loading is

also a good feature.

Riding the Mini Wave

ASSEMBLY Electronics Assembly

Automated selective soldering technology saves EMS facilities time and money.

� By Reed GaitherCEORPS Automation LLCSpokane Valley, [email protected]


Molten solder is pumped through this small nozzle to create a fountain with a directional or spherical shape.

“We have

decreased the cost

of labor by at least

half.”—Todd King,

E.I. Microcircuits


“Handling of PCBs should be

tool-free when possible,” he says.

“Some systems use expensive

and time-consuming tooling for

different sizes of PCBs. [This] can

substantially reduce the usefulness

of the system as an economical and

high-mix production tool.”

Programmability is particularly

important for any machine in a

high-mix assembly environment.

“Software should provide a simple

user interface and utilize scanned

images or Gerber data,” Sackett

says. “It should only take minutes

to select solder points and nozzle

configurations. A simple jog-to-

teach set-up camera could also be

used to program a board,” he says.

For high-mix production, the

system should be able to store

an unlimited array of soldering

programs. To save time and prevent

errors, programs can be triggered

automatically through a bar code

reader.

Filling a Gap

In the past, high-mix, low-

volume assemblers had two choices

for assembling mixed-technology

boards: wave soldering or manual

soldering. “Our first choice was

always wave soldering,” recalls

Todd King, vice president of

operations at E.I. Microcircuits Inc.

in Mankato, MN. “It is the highest

volume and the most economical.

What prevents wave soldering

are unique components and some

tight configurations particularly

in [radio frequency applications],

or large components that cannot

be waved or masked. Then we

[reverted] to hand soldering.”

With production runs between

500 and 10,000 pieces, manual

soldering is costly, not only in terms

of labor, but also in quality control.

Two years ago, the company

invested in its first selective

soldering system. Today, it has

three in-line machines running both

lead-free and standard boards.

E.I. Microcircuits assembles

many boards that require significant

masking or large copper ground

planes, which are difficult to solder

manually. Selective soldering with

a mini wave provides constant heat

like traditional wave soldering

equipment, but with less waste.

“We expect volumes to increase

in these applications,” King says.

“[These boards] will go directly

to selective soldering, bypassing

wave or hand soldering entirely.”

In the past, E.I. Microcircuits

would sometimes run mixed-

technology assemblies through a

wave soldering machine and then

another soldering operation for

difficult through-hole components.

Now, these assemblies go directly

to the selective soldering system.

“It can get in-between deep, tight

parts and navigate around large

components with consistent

repeatability,” says King. “You

simply can’t get that manually,

regardless of how adept the operators

might be. ...We have decreased the

cost of labor by at least half [using

selective soldering],” he says.

Replacing Wave

When Ayrshire Electronics

first began looking at selective

soldering technology, it had some

concerns. James Beard, director

of manufacturing for Ayrshire’s

Oakdale, MN, facility, says the

first machines he looked at were

not flexible or easy to program.

“Everything was customized,” he

recalls. “You designed the board, and

then you had the selective soldering

[machine] designed around it. If you

needed fast changeover, too bad.

Plus, the footprint of the machines

was almost the size of a standard

wave machine.”

Being a high-mix assembler,

Ayrshire needed flexibility. The

company finally invested in a mini-

wave system that can easily switch

from one program to another.

“It’s not tied to one product line

or niche,” Beard says. “It can do

point-to-point when needed, or

drag soldering and a mini wave for

some larger areas if needed. The

Soldering nozzles come in various shapes and sizes to suit specific applications.

Programmability is particularly important for any machine in a high-mix assembly environment. Soldering software should provide a simple user interface and use scanned images or Gerber data.

system is integrated in-line for complete

automated assembly, and the best part is

that the footprint is 3.5 feet by 4 feet.”

After a short while, Ayrshire

completely eliminated wave soldering

on its assembly line. A standard wave

soldering system produces a wave that

is 18 to 24 inches wide, whereas most

PCBs are much smaller. This means the

machine is heating a lot of solder and

producing a lot of dross unnecessarily,

explains Beard.

With their smaller wave nozzles,

selective soldering systems are much

better suited for boards that are 4 inches

wide. The system can accommodate

boards that are more than 4 inches wide

by moving them in a serpentine pattern

over the wave.

Soldering programs can be adjusted

to optimize key parameters, such as

speed, immersion depth, dwell time

and temperature. The net result is that

while the smaller wave nozzle solders

joints at a slightly slower rate than a

traditional wave-soldering machine, it’s

more efficient in the long run when

maintenance, uptime, consumables and

defect rates are factored in.

“We specialize in low- to medium-

volume, high-mix, double-sided,

surface-mount boards with maybe one

or two through-hole parts on them,” says

Beard. “Instead of using a wave solder

[machine, which required] custom

pallets or a masking step, our assemblies

now go directly from the dispensing line

to the selective soldering step and then

on to various inspections.”

Eliminating the wave soldering

system saved Ayrshire approximately

$120 per day in energy costs and

eliminated some 3,500 pounds of dross.

“The dross from selective soldering is

only spoonfuls,” Beard says.

Ayrshire also saved on labor. “When

we went to selective soldering two and a

half years ago, we had 16 people doing

hand soldering during the first shift,

eight people on the second shift, and

four on the third,” Beard recalls. “Today,

we are building the same volume and

same mix of products, and we are down

to six people on the day shift. That’s a

manpower reduction of 75 percent.”

Selective soldering has made

a difference in defect rates, too,

particularly with small boards for radio

frequency applications. “[If there’s] a

tiny icicle on a joint, all of a sudden

you have an antenna and it throws off

the whole board,” Beard says. “That’s

where selective soldering really shines.

It has cut our defects—bridging, damage

to other parts, and so forth—down to

virtually zero.” A


ASSEMBLY ONLINEFor more information on soldering technology, visit www.assemblymag.com to read these articles:� Three Boards in a Fountain.� Soldering Soldiers.� Step up to the Bar.


Electronics Assembly

In some selective soldering systems, the board is held stationary, and the solder fountain moves beneath it. In others, the fountain remains stationary, and the board moves.

Although the small nozzle solders joints at a slightly slower rate than a traditional wave-soldering machine, it’s more efficient in the long run when maintenance, consumables and defect rates are factored in.

Despite the economic hard times,

assemblers in the United States

will still spend more than

$2.5 billion on new assembly

equipment this year, according

to ASSEMBLY magazine’s

13th annual capital equipment spending

report.

Not only that, as the economy works

its way out of the downturn, assemblers

are going to have to work smarter and

more efficiently than ever if they are to

succeed in an increasingly competitive

global economy.

To make sure your company has the

capital equipment it needs to survive

in this kind of environment, be sure

and check out this year’s Assembly

Technology Expo (ATExpo), set for

Sept. 22-24 at the Donald E. Stephens

Convention Center in Rosemont, IL,

immediately adjacent to Chicago’s

O’Hare airport.

As in 2008, ATExpo 2009, which is

sponsored by ASSEMBLY magazine,

will be co-located with the Medical

Design & Manufacturing Midwest

(MD&M Midwest) show and the Green

Manufacturing Expo. Also co-located

with this year’s ATExpo will be

Quality Expo and the new Design &

Manufacturing Midwest and Electronics

Midwest shows.

In addition, ATExpo 2009 will

feature a range of conference sessions,

including a quality track, a design track,

a medical track, a green manufacturing

track, and a track on automation and

assembly.

The latter, which is being sponsored

and organized by ASSEMBLY

magazine, will be comprised of a number

of specialized sessions, including

those on plastics assembly, affordable

automation, lean manufacturing,

compliant design, affordable robotics for

smaller manufacturers, machine vision

and recycling. (See sidebar, page 38.)

Building the Future

As it has been for more than a

quarter century, ATExpo is the one-

stop source for assembly-related

equipment and materials, including

automated assembly systems, adhesive

and solder dispensing machines, robots,

conveyors, parts feeders, circuit board

assembly equipment, adhesives and

sealants, mechanical fasteners, machine

Don’t Miss the Big Show

ASSEMBLY ASSEMBLY EVENTS

Find the tools your company needs to succeed at ATExpo 2009.

� By Adam CortSenior Editor

As the economy makes its way out of the downturn, assemblers will need to work smarter and more efficiently than ever if they are to succeed in an increasingly competitive global marketplace.


vision systems, power tools, presses,

workstations, process monitoring

systems, and test and inspection

equipment.

The show also plays host to dozens

of integrators and machine builders with

experience in assembling everything

from the tiniest consumer gadgets to

high-end medical devices and mission-

critical components for the automotive

and aerospace industries.

This year’s ATExpo will include

a number of what show organizer

Canon Communications describes as

technology-specific areas, including a

sensors and vision area, a wire harness

processing area and a new lean “factory,”

which will feature lectures and a step-

by-step demonstration on how to build

an actual lean production area.

Canon Communications is also

creating an Innovation Briefs Theater,

a 50-seat amphitheater complete with

its own screen, where experts can give

30- to 40-minute seminars on various

technologies.

Co-Located Shows

For those with responsibilities in the

areas of design and planning, this year’s

Design & Manufacturing Midwest show

will include exhibitors featuring the

latest in CAD, CAM and CAE software,

computer hardware and peripherals,

contract manufacturing services, linear

motion devices, material handling

systems, plant engineering products,

motors, drives and other manufacturing

support equipment.

Similarly, Electronics Midwest will

be your one-stop source for the latest

in component insertion and placement

equipment, soldering machines

and everything else you’ll need to

manufacture and package printed circuit

boards.

For those either already a part of, or

planning to become a part of the red-

hot medical-device industry, MD&M

Midwest will bring together many of

the major equipment, materials and

service providers doing business in the

Midwest and beyond.

In fact, the five states comprising the

As the economy gets back on its feet again, assemblers are

going to have to work smarter and better than ever before to

remain competitive. This, in turn, will require not only the latest

technology, but new ways of thinking—both of which will be

the focus of this year’s assembly conference at ATExpo.

On Tuesday, Sept. 22, the conference kicks off with three

tracks: “The Ultimate Plastics Assembly Seminar,” “Lean Manufacturing,” and “How to Profit from Automated Assembly.”

The plastics assembly track will feature industry experts

addressing everything from ultrasonic welding and light-cure

adhesives, to the best ways of placing inserts and using the latest

environmentally friendly materials.

The track on lean manufacturing will include speakers such

as Kevin Duggan, founder of The Institute for Operational

Excellence, discussing how to employ lean techniques to grow

a business in a recovering economy. The automation track will

feature speakers such as Mikron Corp.’s Jim Mueller, who will

explain how designing a new product with assembly in mind

can reduce costs.

On Wednesday, the conference continues with three more

tracks: “Technology for Profitable Assembly,” “Robots and Vision,” and “Preparing for the Economic Recovery.”

The session on profitable assembly will begin with

presentations on resistance welding, crimp quality verification,

and press fits and process monitoring. In the afternoon, the track

continues with a panel discussion on how even small companies

can benefit from robotics. There will also be a presentation

by Denise Coogan, manager for safety and environmental

compliance at Subaru of Indiana Automotive Inc., on how her

plant has cut the amount of solid waste it generates to zero.

The track on robots and vision will include sessions on robots

and the “green” economy, collaborative robots working in close

proximity to people, and how to employ machine vision to

improve your bottom line. In the afternoon, Dr. John Kamauff, a

principal and expert on supply chain management at Archstone

Consulting, will give a pair of presentations titled “North America: the New Low Cost Manufacturer” and “Planning for the Rebound.” In these sessions, attendees will learn how

companies can position themselves to take advantage of the

latest trends in manufacturing.

Finally, the conference will end on Thursday with a pair

of workshops: “Reducing Part Counts and Product Costs Through Compliant Design” and “Lean Workshop: Operating System Design.”

Chairing the session on complaint design will be Sridhar Kota,

Ph.D., a professor of mechanical engineering at the University

of Michigan. Leading the workshop on lean manufacturing will

be Matt Zayko of the Lean Transformations Group.

Individual sessions are about an hour long, and will begin

at 9 a.m. and end at 3 p.m. on Tuesday and Wednesday.

Thursday workshops will begin at 9 a.m. and finish at noon.

For more information, including session abstracts and a

complete conference schedule, go to www.devicelink.com/

expo/atexpo09/conference.html.

Prepare for the Rebound at the Assembly Conference

ASSEMBLY EVENTS


upper Midwest—Illinois, Wisconsin,

Michigan, Indiana and Ohio—are

already home to some 1,800 medical

OEM facilities producing about $20

billion worth of medical devices and

equipment every year. Thanks to the

United States’ rapidly aging population

and continuing advances in medical

technology, those numbers will only get

bigger in the coming years.

Finally, for those looking to either

become a part of the new green

economy or cut their costs through

environmentally friendly technologies,

there is the Green Manufacturing

Expo.

Now in its second year, this event

focuses on sustainable manufacturing

and covers economically sound and

nonpolluting manufacturing processes

that conserve energy and natural

resources.

Products and services featured will

include solar and wind power systems,

recyclable and reusable packaging,

energy management software, and

consulting for energy management,

recycling and waste treatment.

Last but certainly not least, for those

in search of the quickest possible return

on investment for their trade show dollar,

this year’s show will include an hourly

“grab bag giveaway.” Every day of the

show, between 10:30 a.m. and 3:30

p.m., there will be a drawing each hour,

with prizes including MacBook Air

laptops, Best Buy gift cards, iPhones,

and iPod Nanos.

Registration Information

A single entry badge allows attendees

to visit all six shows. If you preregister

online or bring show material with

you on-site, admission to the shows is

free. Otherwise, you will be charged an

expo-only fee of $55 to register on-site.

Online registration is available even on

show days.

For more information, current

exhibitor lists and to register for free

show admission, visit any of the show

web sites: www.atexpo.com, www.

manufacturingweek.com, www.

qualityexpo.com, www.mdmmidwest.

com, www.greenmfgexpo.com and

www.electronicsassemblyshow.com. A

Sponsored by the Lean Factory

Group, comprised of Bosch Rexroth

Corp., Orgatex Americas LLC,

Leonardo Group Americas, and Omron

STI, this year’s Lean Factory exhibit

will demonstrate the importance of a

data-driven approach to line design;

the need to create an environment that

supports lean with the right equipment

and infrastructure; and tools that can be

used to create a visual factory.

Attendees will see presentations

on lean manufacturing; interact with

experts in the field; and take part in the

step-by-step creation of the perfect lean

production environment, culminating

in an actual build demonstration on an

optimum lean line.

Join Us at the Lean Factory!


asb04094seal.indd 1 3/3/09 8:55:44 AM


ProductsGrippers Certified for Clean Room UseGrippers are now certified for use in Class 5

clean rooms according to ISO 14644. Among

the grippers now certified are PGN-plus paral-

lel grippers, the DPG-plus sealed parallel grip-

per, the PZN-plus centric gripper, the DPZ-

plus sealed centric gripper, the MPG miniature

parallel gripper, the MPZ miniature centric

gripper and the SRU rotary module.

SCHUNK Inc.www.schunk.com 800-772-4865

Test, Monitor System Easy to ConfigureThe sigPOD PSV is an out-of-the-box, user con-

figurable system that can be used to test or monitor

virtually any operation during manufacturing, includ-

ing press, torque, vibration, dispense and functional

test. An easy-to-use setup interface allows operators

to leverage an expansive library of processing and

analysis tools. The system can be used on up to eight

channels to allow for greater output without sacrific-

ing quality.

Sciemetric Instrumentswww.sciemetric.com 866-900-7054

Leak Detector Minimizes Operator ErrorMS-60Dry helium mass spectrometer leak detec-

tors can be used to test the integrity of a wide variety

of systems, containers and parts using helium as a

tracer gas. The MS-60Dry is available with a stan-

dard 16 cfm Dry foreline-roughing pump for faster

cycle times and use in clean room applications. The

system’s software allows users to both locate and

measure leaks with ease, at the same time minimiz-

ing operator error and maximizing throughput.

VIC Leak Detectionwww.vicleakdetection.com 631-737-0900


Crimper Accommodates Multiple StationsThe CrimpCenter 36 can accommodate up to six processing stations and is suitable for a use in

a variety of applications employing cross sections from 24 to 12 AWG. Modern manufacturing

materials and a number of new proprietary technologies allow for a compact, economic design

without compromising quality.

Proven state-of-the-art compo-

nents provide outstanding output

rates, while synchronized Ethernet

powerlink ensures fast and con-

tinuous communication between

software and servo drives.

Schleunigerwww.schleuniger-na.com 603-668-8117

Painting Robot Is Compact, FlexibleThe Paint Mate 200iA intelligent mini paint

robot can be used to paint small parts and

offers a cost-effective alternative in applica-

tions that would otherwise require multiple

fixed paint guns. The system incorporates all

the features of the popular LR Mate 200iC,

including wrist load capacity, repeatability and

speed. The robot is extremely flexible and can

be mounted on the floor, on a tabletop, at an

angle or inverted.

FANUC Robotics America Inc.www.fanucrobotics.com 800-477-6268

Reactor H-VR Offers Adjustable Ratio SettingsThe Reactor H-VR is a simple-to-operate,

variable-ratio dispensing system that can be

used to process polyurethane foams and polyu-

rea coatings. Designed for materials that have

extreme differences in viscosity between their

A and B components, the system allows end

users to spray infinitely variable volumetric

ratios ranging between 1:1 and 2.5:1. Maxi-

mum fluid output varies depending on the

ratio setting.

Graco Inc.www.graco.com 877-844-7226

Belt Conveyors AreSturdier, Easy to ServiceTB belt conveyors feature sturdy aluminum

covers to protect their chains and pinions. In

addition to providing superior protection, the

covers make the conveyors easier to service

because they require fewer locking screws.

The conveyors are available in six different

frame widths, from 60 to 250 millimeters, and

can be ordered with either a single or double

belt. The drive unit can be installed horizon-

tally or vertically at any point along the entire

length of the frame.

Montechwww.montech.com

Robot Has ‘Zero’ FootprintThe new overhead-mounted RS3 SCARA

robot is literally a “zero footprint” robot, sav-

ing assemblers valuable floor space. The sys-

tem can be easily integrated into a compact

assembly cell and offers 450 degrees of axis

rotation for omni directional access. It comes

standard with the low-cost, high-performance

Micro PowerDrive RC180 controller to facili-

tate ease of use and reliability.

EPSON Robots www.robots.epson.com 562-290-5910

Adhesive Turns from Blue to ClearThe 3-20794 See-Cure adhesive is a color-

changing material formulated with Ultra-Red

fluorescing technology. It bonds to a variety of

plastics and cures clear in less than a second

when exposed to high-intensity UV light,

enabling faster processing, greater output and

lower assembly costs. The adhesive is bright

blue in its uncured state making it easy to

see on the surface of substrates, in deep wells

or when sandwiched between two layers of

material.

DYMAX Corp.www.dymax.com 877-396-2963

Microscope Records High-Speed MotionThe VW-6000 motion analysis microscope is

the world’s first microscope with high-speed

magnified video-capture capabilities. The sys-

tem can record up to 24,000 frames per second,

making it possible to film moving targets that

cannot be otherwise captured. Because it is

small and portable, the system can be used on

the factory floor as well as in the lab.

Keyence Corp. of Americawww.keyence.com/vw

Posts, Pins Facilitate Light AssemblyNew post-and-pin combination includes pins

molded in white polycarbonate material and

posts in various lengths molded in white

polyethylene. The fasteners are intended for

one-time use and provide a cost effective

means of creating a lightweight assembly.

One size pin fits all lengths of posts. Posts

are available in lengths from 1/2 inch to 1 1/4

inches.

Micro Plastics Inc.www.microplastics.com 800-466-1467

System Handles Sensitive MaterialsThe Dos A300 dispenser can be used to

process everything from liquid, self-leveling

materials to abrasive resins. It is especially

well suited to handling liquid and medium-

viscosity polyurethanes, silicones and epoxies

with or without filling materials. It can also be

used for dispensing humidity-sensitive materi-

als that need to be processed under vacuum.

The system can be configured as a stand-alone

manual workstation or as part of a larger pro-

duction line.

Scheugenpflugwww.scheugenpflug.de

Mobile Workstation Safeguards LaptopsThis mobile laptop computer workstation pro-

vides a secure place to both store and use a

laptop, at the same time positioning it at a com-

fortable work height. The station’s four large-

diameter swivel casters ensure easy rolling and

maneuverability. The casters can be locked for

greater safety and stability while working. The


station provides a workspace that is 42 inches

wide, 26 inches deep and 38 inches high. Cus-

tom dimensions are also available.

Creform Corp. www.creform.com 800-839-8823

Slides Available in Five DaysCustomized LSK linear slide kits are now

available in just five days, dramatically cutting

lead times and reducing the overall cost of

system assembly. The kits are compatible with

any linear slide, belt or ball screw actuator,

and any motor or gearbox. Standardized com-

ponents are available for those applications

requiring extra stiffness or dampening. Each

kit includes all necessary mounting hardware,

making installation as simple as tightening

down the bolts.

GAMwww.gamweb.com 888-GAM-7117

Rails Provide Accuracy, Cost SavingsLFS 12 Series low-profile linear rails and car-

riages can be used in those applications that

require low cost and accuracy, such as door

enclosures and transfer systems. Each linear

rail and carriage set employs a set of mating

V-groove rollers. The standard rail length is 3

meters, but custom lengths are available.

Techno Inc. www.technoautomation.com 800-819-3366

Sensors Combine Accuracy, ValueThe OD Value line of optical displacement

sensors provides high-accuracy performance

at a competitive price with a variety of inter-

face capabilities for use in a wide range of

quality control applications in the automo-

tive, robotics and electronics-semiconductor

industries. The sensors can measure targets

regardless of color or reflectivity and include

an easy-to-read bar graph display for fast

installation and maintenance.

SICKwww.sickusa.com

268 METRIC HINGESfor a cleaner environment

RoHSCOMPLIANT

All Metric Small PartsT. 516.302.0152 F. 516.302.0153www.amsp.biz

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Solutions for your testrequirementsService problems?

Trust your measurements?

Calibration trouble?

Feeling abandoned after the sale?

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Leak, Mass Flow andElectrical Testers

starting at $2990.00

Products


Dispense, Spray System Includes Tilt FeatureThe Precisioncoat spray and dispense system

now includes a programmable tilt and rotate

feature, needle calibration and a vision system

to help customers achieve maximum effi-

ciency, flexibility and accuracy as they spray

and dispense coatings onto printed circuit

assemblies and other devices and substrates.

The programmable tilt and rotate feature, in

particular, allows users the flexibility of five

separate axes to coat alongside and underneath

a wide variety of components.

Specialty Coating Systems www.scscoatings.com

Pipette Enables Contaminate-Free DispensingThe Stepper pipette enables contaminate-free

dispensing in a simple-to-operate, handheld

system. The dispenser incorporates a light-

weight, ergonomic design and is constructed

of aluminum for maximum durability. Users

can dispense a variety of low- to medium-

viscosity materials. The pipette is available in

three sizes and offers positive displacement

dispensing in a range of volumes from 0.01 to

1.00 milliliter. Each pipette can dispense up to

100 shots per fill.

Tridakwww.tridak.com 860-626-6700

Readers Fill Multiple NichesHS-1 and HS-2D handheld readers provide

out-of-box, plug-and-play performance and

can be plugged into a number of standard

Microsoft Office programs, including Word

and Excel. The HS-1 is lower-cost reader for

use with linear barcodes, such as those found

on printed black-and-white labels. The HS-2D

reader is a higher performance model that can

INDUSTRIALROBOTS

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&&Custom AdhesiveCustom AdhesiveEncapsulant PackagingEncapsulant Packaging

ISO9001:2001 – Authorized Dow Corning Repackager

Specializing in packaging adhesives and encapsulants in convenient syringe and cartridge systems, ideal of Electronic assembly.

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be used to decode both linear barcodes and

2D symbols in a wide range of environments,

including clean rooms.

Microscanwww.microscan.com

Wire Stripper Collects Insulation ResidueThe Model DV1 twin-wheel wire stripper with

integral dust collector can be used to strip

magnet, enamel and film-insulated wires, as

well as round, rectangular and square section

wires with insulations such as Formvar,

ML, Dayglass, Isonel and Polythermaleze.

The system’s integral dust collection traps

insulation residue as it is removed from the

wires during stripping.

Eraser Inc.www.eraser.com 315-454-3237

Robotic Cleaner Handles Heavier LoadsEcoclean flexible robotic cleaners can now

accommodate industrial parts weighing up to

300 kilograms, thanks to a new conveyor com-

ponent that reorients the parts being cleaned

via a tilting station, thereby allowing the robot

to handle heavier parts than in the past. The

system is especially well suited to cleaning

parts with complex geometries, like those

in the automotive and commercial vehicle

industries.

Dürr Ecocleanwww.durr-ecoclean.com

TFT Systems Available with Hollow ShaftsTorque Functional Test (TFT) systems pro-

viding monitored and measured amounts of

torque during assembly and test operations are

now available in a hollow shaft configuration.

The new feature allows operators to access

components with tools or sensors inserted

through the center hole at the same time the

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VLB-900M Mini Locking Bit Comes With the Most Reliable Screwfeeding System on the Market.

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Products

components are being processed. The TFTs employ servomotors, pre-

cision position sensing feedback technology and extremely accurate

torque transducers to produce controlled torque inputs and feedback

monitoring.

Promess Inc.www.promessinc.com810-229-9334

Tubing Good for Appliances, Food IndustryEthelplas tubing is extruded from nontoxic, 100 percent virgin linear

low-density Polyethylene resin for use in commercial and household

appliances, the food industry and laboratory testing equipment. It

provides good resistance to chemicals and is nonconductive. The tub-

ing is available in nine

different sizes, ranging

from a 1/16-inch inner

diameter to a 5/8-inch

inner diameter.

Ark-Plas Products Inc.www.ark-plas.com 870-453-2343

Laser Scanner Is Precise, PortableThe SLP-500 3D laser scanning probe is a high-precision probe deliver-

ing virtually noise-free scan data for use in the automotive and aerospace

industries. The system

provides a laser line

length of 50 millime-

ters and scans at very

high speeds, making it

ideal for use in scan-

ning mid- to large-

sized objects, such

as molds, stampings

and sheet metal. The

probes are portable and can be easily integrated with a coordinate mea-

suring machine (CMM) arm.

Laser Design Inc.www.laserdesign.com 952-884-9648 Stains Are Environmentally FriendlyDYKEM water-based stains can be used to permanently color code

springs, small parts, tools and finished assemblies. The stains produce

little odor and emit few VOC’s. Their non-xylene based formulation is

resistant to motor oils,

transmission fluids

and most other work-

related compounds,

such as greases and

cutting fluids. The

stains can be applied

by brushing, spraying

or dipping. Dry time is

less than 15 minutes.

ITW www.dymon.com 800-443-9536

Main Catalog Available Online

Applications include:small linear slides, medicalequipment, instrumentation,packaging, material handling,rotary actuators and more

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Clamps Combine Accuracy, Ease of UseZero Point clamps offer ease of alignment,

high-accuracy positioning and high clamping

forces. They can be used with either hydraulic

or pneumatic actuation. Each clamp employs a

series of balls that roll freely in a form-fitting

ball channel that allows them to easily reposi-

tion themselves, allowing heavy fixtures to

self-align easily. All components are made of

stainless steel.

Jergens Inc. www.jergensinc.com 800-537-4367

Workbenches Are Sturdy, EconomicalThe Arlink 7000 workbench is a cost-effective,

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Gripper Configured for Solar ProductionThe new SWG vacuum gripper is configured

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surface of the gripper. The gripper can also be

safely used in a clean room environment. Schmalz Inc. www.vacuworld.comasb0809

Gantries Provide Speed, PrecisionAGS15000 series Cartesian gantries incorpo-

rate a planar design that minimizes dynamic

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acceleration.Aerotech www.aerotech.com 412-963-7470


Products

www.krygierdesign.com

CUSTOM ASSEMBLY EQUIPMENTQUALITY CONTROL SYSTEMSSPECIAL MACHINERYSPECIAL FIXTURESPRECISION CNC MACHINING

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Ace Controls ....................................................... 45

AMSP All Metric Small Parts .......................... 42

Assembly Technology Expo 2009 .................. 33

ATEQ .................................................................... 42

Cincinnati Test Systems ................................... 27

Conductix-Wampfler.......................................... 32

DEPRAG Inc. ....................................................IBC

Dymax ................................................................... 25

Edgewater Automation ..................................... 13

EFD ..........................................................................1

Ellsworth Adhesives ...................................29, 43

I & J Fisnar Inc. ...................................................BC

Janome Industrial Equipment USA Inc. ......... 45

Lista International Corp. ................................... 15

PHD Inc................................................................ 44

ProLine ....................................................................4

Promess ............................................................. IFC

Quality Bearings & Components .................... 12

Robotic Industries Association ....................... 11

Saejong Industries ............................................. 43

Sankyo .................................................................. 24

Schleuniger Inc. .................................................. 10

Schmidt Technology .............................................5

Schunk Inc. .............................................................3

Sciemetric ...............................................................7

Sealant Equipment & Engineering ................. 39

Technifor ............................................................... 29

Techno .................................................................. 21

Techno Sommer ................................................. 12

Turck ...................................................................... 28

Visumatic Industrial Products Inc. .................. 44

Weiss North America ........................................ 26

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In the past two columns, I

have used the A3 improve-

ment process to explore some

of the subtler but broad skill

sets and mindsets of lean. A3

can be a helpful method to

guide your thinking, and it enables

greater collaboration and coach-

ing. Last month, I focused on the

imperative of good problem state-

ments and the thinking that goes

into them. This month, I move

to the next quadrant of the

A3, defining and clarifying

the current condition.

This section of an A3

can be populated with data,

stories, pictures and anything

else that helps explain the

current condition. It should

explain why you are getting the

results that you are getting and

where you must focus to make

the required changes. But there is

more to this section than simply

cutting and pasting your favorite

Excel chart. The underlying

function of this quadrant is to

drive learning and knowledge.

Lean businesses constantly focus

on generating new knowledge

about how their processes and

organizations really work. In

this part of the A3 process, you

should focus on that purpose.

There are two fundamental

questions that help in this process.

The fi rst is, what do I need to learn

more about? Another way to phrase

it would be, what specifi cally do I

not understand in the areas where

I need to gain knowledge? There’s

no need to gather “new” knowledge

about something you already

understand. The assumption is that

there is something you don’t quite

understand, so focus on exactly

what that might be. This requires

humility and curiosity. You must

be willing to use what I consider

one of the more powerful phrases

a leader can use, “I don’t know.”

And you must have the curiosity to

invest time and energy in pursuit

of that knowledge.

The second fundamental

question is, by what method can

I learn this knowledge? There

are many methods you may

deploy. I have written more than

once about the power of direct

observation. Whenever you have

to suspend your assumptions and

trim your fi lters, you are more

open to what is really going on.

Going directly to the point of

activity, whatever and wherever

that is, can greatly expand your

knowledge.

There are other methods.

You should deploy the simplest

approach to gain the knowledge

you need. The “5 Why”

problem-solving method is a

good example. In the “5 Why”

method, you keep asking “why”

about a condition until you get

to the root cause. Invariably,

you’ll hit the root cause by the

fifth time you ask “why.” The

intent is not documentation or

ensuring a particular rigor. It is

a knowledge discovery process.

That, I believe, is it’s real

value. Developing and testing a

hypothesis is also a good way to

generate knowledge.

Why bother? The fact is,

you must close your knowledge

gaps before you can close your

performance gaps. Closing

performance gaps where the

knowledge is already clear

and available is often simply

a matter of execution. If you

only need to execute what

you already know, then the

A3 won’t help you. The

thinking process enables you

to close performance gaps that

are more challenging. To close

those gaps, new knowledge,

insight and maybe even wisdom

are required. If you try to close

the performance gap before

you close the knowledge gap,

you will ultimately end up back

where you started.

The second quadrant of the A3

is meant to capture the current

condition. The ability to do this is

found in those two key questions.

What do I need to learn more

about? And, how can I learn it?

Keep these two questions in mind,

and you will move forward with a

high probability of success.

LeadingLean

Close knowledge gaps before closing performance gaps.

Jamie FlinchbaughPartnerThe Lean Learning CenterNovi, MI

Close the Knowledge Gap

Email Jamie with comments [email protected] his recommended bookssee tinyurl.com/leadinglean


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