ASSEMBLY

August 2009 www.assemblymag.com

Auto Supplier
Rides Winds
of Change
pg 14

Ophthalmic Assembly 22
Marking Dots, Stripes 30
Selective Soldering 34
ATExpo Preview 37
See us at ATExpo, Booth 507
 Be the first to experience
the future of precision fluid dispensing.

ATExpo, Booth 705

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 August 2009 Vol. 52, No. 9
22

ASSEMBLY 66

COVER STORY 30
䡵
14 Automotive Supplier Rides Winds of Change
When 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
34

FEATURES DEPARTMENTS

䡵
22 Better One or Better Two? Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Time to back health care reform.—John Sprovieri
Ophthalmic device manufacturers keep an eye on new
technology.—Austin Weber Automation Profiles . . . . . . . . . . . . . . . . . . 8
System handles fragile components.—John Sprovieri

䡵
30 When All You Need Is a Dot
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.—John Keating
and Claude Bergeron
Quality in Assembly . . . . . . . . . . . . . . . . . . 9
Software helps assemblers manage quality tasks.
—John Sprovieri
We Fed It . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System feeds, assembles springs.—John Sprovieri
New & Noteworthy . . . . . . . . . . . . . . . . . . 12
All-purpose gloves made from bamboo.

䡵
34 Riding the Mini Wave
Automated selective soldering technology saves EMS
facilities time and money.—Reed Gaither
Assembly Lines . . . . . . . . . . . . . . . . . . . . . 16
Group launches wind energy data base.
Assembly in Action . . . . . . . . . . . . . . . . . . 18
Single-cable camera maximizes efficiency.

䡵
37 Don’t Miss the Big Show Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Find the tools your company needs to succeed at Classified . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ATExpo 2009.—Adam Cort

NEXT MONTH
Automating Battery Assembly
Robot Guidance
Assembling With Lockbolts
Cover photo courtesy Mariah Power Assemblers Get a Lift

2 ASSEMBLY / August 2009 www.assemblymag.com

See us at ATExpo, Booth 133
 ASSEMBLY ONLINE
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ASSEMBLYtv and the interactive AssemblyBlog blog page. Ophthalmic Devices
Engineers are developing an artificial retina that includes 60
implanted electrodes to help patients with impaired vision.

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 Editorial ASSEMBLY ®

1050 IL Route 83, Suite 200

Bensenville, IL 60106-1096
Phone 248-362-3700
Fax 630-227-0204

Time for Health Care Reform

TOM ESPOSITO

R
ecently, while cutting some fruit for breakfast, I Publisher
nearly sliced off the tip of my left index finger. After espositot@bnpmedia.com
much bleeding, abundant foul language, and a trip to BILL DEYOE
the emergency room, I’m happy to report the finger was Associate Publisher
deyoew@bnpmedia.com
saved.
Including a tetanus shot and skin glue, the bill for my JOHN SPROVIERI
Editor
mishap totaled an astounding $982. I shudder to think of sprovierij@bnpmedia.com
the bill had I been in a serious accident. Thankfully, I have AUSTIN WEBER
health insurance, but how long will that continue when Senior Editor
treatment for a simple cut costs nearly $1,000? webera@bnpmedia.com
Almost all U.S. manufacturers offer health benefits to ADAM CORT
their employees, but the rising cost of those benefits is impairing their ability Senior Editor
corta@bnpmedia.com
to hire workers, battle overseas competitors, develop new products, and invest
DONALD E. HEGLAND
in assembly technology. Employer-sponsored health insurance premiums have Editorial Director Emeritus
nearly doubled since 2000, a rate three times faster than wages. In 2008, the
MIKE ROBINSON
average premium for a family plan purchased through an employer was $12,680, Art Director
which is nearly the annual earnings of a full-time minimum wage job. According robinsonm@bnpmedia.com
to a 2008 survey conducted by the National Association of Manufacturers, 55 AMANDA PODINA
percent of small and midsized manufacturers reported that their health care costs Marketing Coordinator
podinaa@bnpmedia.com
increased by more than 10 percent during the past year.
The 2008 election seems finally to have goaded Congress to action. In July, LISA WEBB
Production Manager
the House and Senate released draft reform bills. The bills are too big to be webbl@bnpmedia.com
elaborated here, but here are a few key provisions. CAROLYN PERUCCA
People who get insurance through their employer would retain that coverage. Buyers Guide Project Leader
A new Health Insurance Exchange would be created so small employers and peruccac@bnpmedia.com
uninsured individuals could comparison shop among private and public insurers. CINDY WILLIAMS
Over time, the exchange would be opened up to all employers as another Corporate Reprint &
Trade Show Coordinator
choice for covering their employees. Premium subsidies would be provided to williamsc@bnpmedia.com
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
CORPORATE DIRECTORS
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 Publishing Timothy A. Fausch
most expensive health benefits plans from employers. Publishing John R. Schrei
Just as there can be no one solution to our increasing energy demands, health Audience Development Christine A. Baloga
care reform must take a multipronged approach to the myriad factors that drive Custom Media Steve M. Beyer
up costs. That means legislators on both sides of the aisle must swallow some Corporate Strategy Rita M. Foumia
bitter medicine. Sorry, Democrats, tort reform must be part of the health care bill. Information Technology Scott Kesler
Production Vincent M. Miconi
Too bad, Republicans, but a public option should be included in the insurance
Finance Lisa L. Paulus
exchange. Creative Michael T. Powell
Whatever bill emerges from Congress—and we must demand a legitimate Marketing Michele Weston-Rowe
proposal this year—manufacturers should get behind it. The worst we can do Directories Nikki Smith
is nothing. Human Resources Marlene J. Witthoft
Conferences & Events Scott Wolters
Clear Seas Research John Thomas

BNP Media Helps People

Succeed in Business with
Superior Information
6 ASSEMBLY / August 2009 www.assemblymag.com
See us at ATExpo, Booth 134
 Automation
Profiles
System Handles Fragile
Components
The glass ampoule is only 0.004 inch thick and very fragile.
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.
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 efficiently 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 filter tip. A solvent bonds
the filter to the tube. The ampoule is only 0.004 inch thick and
very fragile. In this profile, 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 first 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 confirms the presence, length and integrity
8 ASSEMBLY / August 2009 www.assemblymag.com
of the glass. At station four, the filters are pressed into the tubes to
complete the assembly and retain the ampoule.
The fifth 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 filters. 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 sprovierij@bnpmedia.
com, or call 630-694-4012.
 Q UALITY in ASSEMBLY

Software Helps Assemblers

Manage Quality Tasks
I
n these days of far-flung supply chains and the Food and Drug Administration.
When updated multiple assembly locations, even small and At that point, managers can think about iden-
midsized manufacturers can have difficulty tifying the root cause of the problem and how to
instructions are logged keeping everyone in their organizations on the correct it. Say, for example, an operator was using
same page. If a new standard or regulation affects a machine incorrectly because the work instruc-
into the system, the your assembly process, can you be certain every- tions were out of date. The CAPA module can
one gets the message? If an assembly-related trigger a request to update the instructions in the
software alerts every defect is reported in the field, can you be sure the document management module. The “owner” of
mistake isn’t repeated? the document would know to update the instruc-
operator to the new You can, with web-based enterprise compli- tions and get any necessary approvals.
ance and quality management software, says When the updated instructions are logged into
procedures. Nikki Willett, vice president of marketing and the system, the training and certification module
regulatory affairs at is alerted to ensure that every operator who uses
Pilgrim Software in that machine knows the new procedures. This
Tampa, FL. Pilgrim’s can be as simple has having each operator sign
product consists of off on the new instructions. “Or, you may want to
seven interrelated, have the manager confirm that the operators have
customizable modules read it,” says Willett. “Operators may have to go
that cover audit man- through a checklist or take a small exam. They
agement, training and may even need classroom or online training.
certification, calibra- ...And because our software can be integrated
tion and maintenance, with other business software, employee records
s u p p l i e r q u a l i t y, can be automatically updated to reflect that they
document manage- have completed the training, which they may
ment, complaint han- need for their job certification.”
dling, and corrective Perhaps the cause of the problem wasn’t an
and preventive action outdated work instruction, but a machine that
Web-based enterprise (CAPA) management. A key feature is the soft- was out of specification. The calibration and
compliance and quality ware’s ability to integrate with other software, maintenance module can tell management when
management software can such as enterprise resource planning systems, the machine was last calibrated or serviced, and
help assemblers address
manufacturing execution systems, product life it can notify maintenance personnel to make an
quality problems whenever
cycle management software, human resources adjustment or replace a part.
and wherever they occur.
Photo courtesy CEA software, and call-center systems. If the problem was faulty parts from a supplier,
Technologies Inc. The top priority of any manufacturer is to the supplier quality module gets triggered. “That
address quality problems whenever and wher- could impact the rating of the supplier,” says Wil-
ever they occur. The CAPA management module lett. “You may want to requalify that supplier. You
captures these problems from multiple sources. may even want to change suppliers.”
“It can be a customer complaint,” says Willett. “It If ISO or FDA certification is necessary, the
For reprints of this can come from your MES, because of a problem audit management module can help engineers
article, please contact on the shop floor. It may be an issue with incom- prepare for audits and deal with their findings.
Cindy Williams at ing parts from a supplier. It may come from a “Auditors will come through with their ques-
williamsc@bnpmedia.com piece of equipment that’s out of spec.” tions and checklists,” says Willett. “They may
or 610-436-4220 ext. 8516. When a problem is identified, a number of find some issues and...make recommendations
decisions need to be made quickly. Does the pro- for improvement. Engineers can use the soft-
duction lot need to be contained? Has it already ware to enter their plans for correcting those
entered the distribution pipeline? Software tracks issues. Some of the auditor’s findings may be so
■ By John Sprovieri it down. In the case of a medical device, the soft- critical that engineers may want to escalate to a
Editor ware can also generate an electronic report for CAPA.” A
www.assemblymag.com August 2009 / ASSE M B LY 9
WE FED IT
System Feeds, Assembles Springs
S
prings are tough to feed. They’re flexible,
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 Versa-Stack consists of a servo- The Feedscape is designed to feed parts with
driven rotary indexer with a custom dial a high diameter-to-length ratio, such as washers,
plate. Mounted radially around the edge retaining rings, wave washers, Belleville springs,
of the plate are pins for holding tubular seals and bearings. Instead of handling parts by
parts. Photo courtesy Centricity Corp. their outer surfaces, it handles parts by their inside
Our Box Makes It Easy
Schleuniger’s semi and fully automatic transfer systems deliver
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TransferModule
6000
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10 ASSEMBLY / August 2009 www.assemblymag.com
asb08094schl.indd 1
䡲 By John Sprovieri
Editor
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 flip, shingle or fall
off. The Feedscape does not require a vibratory in-
line track, and tooling is inexpensive and flexible.
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 final
position, where the small spring is dropped onto
the pin. If the assembly requires the large spring,
the first 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.
TransferModule
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New Robots Have Speed, Reach

The 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 USA
846-433-1980
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See us at ATExpo, Booth 541

12 ASSEMBLY / August 2009 www.assemblymag.com

asb02094techsomm.indd 1 1/6/09 3:49:44 PM
Meter-mix Systems Fill Many Niches
Meter-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 Flexible

The 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.
Schleuniger
603-668-8117
www.schleuniger-na.com

See us at ATExpo, Booth 446

www.assemblymag.com August 2009 / ASSE M B LY 13
 Automotive Supplier Rides
the Winds of Change
䡲 By John Sprovieri
Editor

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 Since April, MasTech has been assembling 100 turbines per month—a
some $1.5 million on new equipment. “We built robotic [and] manual number that could increase to 1,000 per month within a few years.
Photo courtesy Mariah Power
welding tools,” says John Holcomb, MasTech’s general manager. “We
built custom material handling equipment and racking. We bought The turbine’s aluminum airfoils are produced by Whitehall Industries
new machine tools.” Inc. in Ludington, MI. Steel parts come from Alro Steel Corp. in

“It’s been our desire since Day 1 to Jackson, MI. The inverters are assembled by Amptech Inc. in Free
Soil, MI. Boxes and crates are made by Norton Packaging Corp. in

make the largest economic impact in Grand Haven, MI. At least three other Michigan companies are also
part of the supply chain.

the smallest geographical area.” “It’s been our desire since Day 1 to make the largest economic impact
in the smallest geographical area,” says Holcomb. “The only components

—John Holcomb, MasTech
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 five years.”
The Windspire is 30 feet tall and 4 feet wide. It includes a high-
efficiency 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.
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 sprovierij@
bnpmedia.com, or call 630-694-4012.

14 ASSEMBLY / August 2009 www.assemblymag.com

2 people. 1 tool. Infinite configurations.

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Assembly Lines
Inventions
Forecasts
Mergers
New facilities
Deere & Co.
Group Launches Wind Planning Russian
Energy Database Expansion
MOLINE, IL—Deere & Co.
says it is prepared to “significantly
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 significant 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
The Great Lakes WIND Network has created an online database to its Russian manufacturing capac-
help wind energy companies locate suppliers and other renewable
ity for agricultural equipment by
energy organizations.
early 2010. Ultimately, with the
CLEVELAND—The Great Lakes WIND Network, an interna- support of the government of the
tional wind energy supply chain advisory group, has launched a new Russian Federation, Deere could
web-based WIND Energy Supply Chain Database and Mapping envision a series of significant
System, available online at http://maps.glwn.org/wind/, to promote investments over the next five to
the growth of the wind power industry. seven years in expanded capacity
The site features an interactive map and a searchable wind supply for manufacturing and supporting
chain database containing the profiles of more than 1,000 manufac- all types of Deere equipment.”
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, EFD Inc. Wins
economic development officials, consultants and other wind power Solar Award
supply-chain partners. EAST PROVIDENCE, RI—
“The wind energy sector is the fastest growing industry in North Dispensing equipment manufac-
America. By linking buyers, sellers and other industry partners, we turer EFD Inc., a subsidiary of
believe this system can be a catalyst for business expansion, invest- Nordson Corp., has won the 2009
ment and new jobs,” says network director Ed Weston. “We are very International Solar Cell Award for
excited at the prospect of being able to service our global network best technical product.
with a single site that supports supply chain needs.” Presented at the 2009 InterSolar
Access to the site is free. To register with the database, visit Exhibition in Munich, Germany, the
www.glwn.org, select “Get Listed,” and complete a Wind Capabili- award comes in recognition of the
ties Profile to start the registration process. company’s new PV cell ribbon and
16 ASSEMBLY / August 2009 www.assemblymag.com
bus bar attachment methodology: a
point-to-point soldering process that
uses a lead-free solder paste and
flux 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
flux, 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 Office
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-Pacific 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 finishing,
medical device, semiconductor and
optical components industries.
Volvo Kicks Off
Fuel Cell Initiative
GOTEBORG, Sweden—Volvo
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 benefit 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 flexible “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 confidence
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 first 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-specific features.
Stäubli robots fulfill 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.
Canon Communications’ trade show in New York continues to grow,
despite the tough economic climate.
www.assemblymag.com August 2009 / ASSE M B LY 17
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.
Assembly in Action
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.
For reprints of any
Assembly in Action article,
please contact Cindy Williams
at williamsc@bnpmedia.com
or 610-436-4220 ext. 8516.
18 ASSEMBLY / August 2009 www.assemblymag.com
Single-Cable Camera
Maximizes Efficiency
C
omau 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-
field, 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
efficient 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.
Comau engineers wanted to reduce
the amount of cabling connecting
the robot-mounted camera to the
robot controller.
“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
 off parts that are incorrectly To develop the application, Rixan
oriented and allow through engineers first used the Melfa-Vision
only those parts that are po- software to calibrate the robot in rela-
sitioned correctly. tion to the feeder. They then put a part
Historically, because of in the robot gripper and “jogged” the
the various hard-tooled robot over to the feeder where it set the
orientation features that part down on the plenum. In this way
are required, this kind of engineers “taught” the robot to pick up
equipment has been very the part in this orientation and at this
part-specific. However, the point on the plenum.
robotics company Rixan Once the robot had been taught how
Associates Inc. has devel- to pick up the part, Rixan’s engineers
oped a new flexible vibrato- used the Cognex camera’s PatFind
The new software allows a robot to both pick up parts and ry bowl feeder that includes object-location tool to draw a rectangle
position them in space using a single camera. a robot and machine vision around the part on the screen, thereby
system to orient multiple allowing the vision system to automati-
switch that provides power down a Cat6 parts using a single system. cally recognize the part as it moves
Ethernet cable at distances up to 100 Rixan originally developed the across the plenum.
meters. By eliminating the need for any system to load dozens of different In operation, when it sees a part, the
additional cables, the Power over GigE aerospace fasteners into a press, a system first sends a signal to stop the
Camera minimizes the risk of cable fa- task that was previously
tigue and greatly improves the integrity performed by hand and
of a vision system. would have otherwise
According to Falcone, Comau also required installing many
liked the camera because of its robust different feeders to
design and performance features. “The automate.
camera is neat, complete and well engi- The new system em-
neered. The lock-style connections are ploys a vibratory bowl
strong, reliable, industrially accepted feeder that randomly pres-
M8 connectors. The integrated UV ents the parts to the vision
filter mounted in front of the camera’s system, which in turn,
face eliminates the need to buy and in- stops the feeder when it
stall a separate filter to show true col- sees the correct part in
ors. This high-quality camera allows us the correct orientation so
to provide our customers with an over- that a robot can load the
all lower cost system,” he says. part into the press. The The system employs a vibratory bowl feeder that randomly
For more on machine vision, visit parts are presented on a presents the parts to the vision system, which in turn, stops the
feeder when it sees the correct part in the correct orientation.
www.baumerelectric.com/usa or call semitransparent, backlit
800-937-9336. plenum, so the vision sys-
For more on automation, call 248- tem can easily identify them. The parts feeder. After the feeder has stopped, the
353-8888 or visit www.comauinc.com. that are not picked automatically recycle vision system acquires one last image to
into the bowl. The result has been a 20 determine the exact position of the part
percent increase in productivity and one and calculate its angle of presentation.
Vision Enables Feeder to less operator to tend the press. The robot then moves to the location
Critical to the success of the system of the part, twists its wrist to match the
Handle Multiple Parts has been its In-Sight 5401 vision sys- part’s orientation, picks up the part and

T raditional vibratory bowl feeders use tem from machine vision manufacturer sends a signal to restart the feeder.
a helical shelf-like inclined ramp Cognex Corp., which is integrated with Most of the parts in the aerospace
winding up from the bottom of a bowl an RV-6SL-S11 robot and Melfa-Vision fastener application are symmetrical
to a discharge passageway. The pas- software from Mitsubishi Electric. top to bottom so they can be identified
sageway’s reciprocating motion pushes Rixan chose the In-Sight 5401 because from their silhouette alone. However,
the parts up the ramp. Obstructions, of its processing power and the fact that in those instances where a part has two
cutouts and other orienting devices are it can acquire up to 60 complete eight- distinct sides, the Cognex PatMax tool
arranged along the passageway to topple bit images per second. can be used to recognize which side is

www.assemblymag.com August 2009 / ASSE M B LY 19

Assembly in Action

up. Top-down lighting is used options like speed enhance-

for parts in which pattern ment, next-generation un-
recognition is required. White derstencil cleaning technol-
light is used for some parts, ogy and automatic board
while glare-free polarized support, as required.
lighting is used for others. “It’s no coincidence that
“A key to the success of DCI has been named to
this application is the ease-of- Fortune Small Business
setup, accuracy and reliability magazine’s list of the fastest
of the Cognex In-Sight vision growing small companies
sensors,” says Rixan Associ- for the past two consecu-
ates President Stephen Har- tive years,” says DCIs vice-
ris. “The PatMax tool that we president of business devel-
use to recognize part features opment Jay Gillam. “When
is much faster and more ac- your top priority is ensur-
curate than other comparable ing your customers receive
industry tools that we have outstanding service and su-
seen. The easy integration be- perior quality products on
tween Cognex vision sensors time every time, business
The screen printer’s scalability means it can be modified to meet DCI
and Mitsubishi robots drasti- Inc.’s future manufacturing needs as well as those in the present. success is inevitable. Our
cally reduces the amount of addition of DEK’s Horizon
time required to develop vision-enabled system’s quick setup and changeover 03i is just one more example of this
robot applications and in most cases times, as well as its new HawkEye print commitment.”
eliminates the need for writing a single verification inspection feature. For more on custom electronics man-
line of code.” “We evaluated several screen printing ufacturing, call 888-824-9412 or visit
For more on machine vision, call 508- systems,” Morgan says. “The capability www.dciincorporated.com.
650-3000 or visit www.cognex.com. of DEK’s Horizon 03i coupled with For more on screen printing systems,
For more on parts feeding and the staff’s depth of knowledge and visit www.dek.com.
automation, call 937-438-3005 or visit process expertise made our decision an
www.rixan.com. easy one. With the Horizon platform’s
new scalability, future-proofing and Workbenches Harmonize
ability to customize, we can modify
With Design Goals
Screen Printer Adapts to the system to meet our manufacturing
Changing Needs requirements as our business changes
and grows.” O ne of the goals of the school of
architecture at the University of

D CI Inc., in Olathe, KS, designs and DEK’s entire

manufactures electronics compo- Horizon line of
nents and subassemblies for custom- screen printers
ers in a wide range of industries. The includes mo-
company specializes in the design and torized sten-
manufacture of specialized custom liq- cil alignment,
uid crystal displays, light emitting di- fast product
ode displays and operator interfaces. changeover, 2.0
Recently, the company expanded its Cpk print pro-
electronics manufacturing capacity by cess capability
implementing a new Horizon 03i fully and Six Sigma
automatic screen-printing system from production per-
electronics assembly equipment manu- formance. The
facturer DEK USA Inc. system’s In-
According to DCI chief operating stinctiv V9 user
officer Mike Morgan, the company interface allows
went with the Horizon 03i because of manufacturers When the school of architecture at the University of North Carolina went
its high print quality and ease of use. to seamlessly in- shopping for new workbenches, it ended up going with a set of stations
Morgan says his company also likes the tegrate advanced from industrial workstation manufacturer Lista International.

20 ASSEMBLY / August 2009 www.assemblymag.com

 LMS Move It Island Ad - Assembly.ai 5/30/2007 12:01:35 PM

North Carolina in Charlotte is to supply these workbenches within a we didn’t use it by the given deadline,
help students “apply strategic think- very tight window of time—about we’d lose it. Fortunately Lista came
ing to environmental problems.” It eight weeks to be exact. This through, not only on time, but with
was therefore only natural that when included about one week for delivery completely assembled products.
the school needed a new set of work and installation,” he says. “At the Many of the other bidders were
desks, the students should take part university level, we call the money delivering only parts. Lista provided
in the selection process. that’s left over from the annual a ready-to-use solution.”
“Our existing desks had worn out budget ‘one-time money.’ This is For more on workstations, call 800-
their welcome,” says Ken Lambla, what we were working with, and if 722-3020 or visit www.listaintl.com.
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 USING TECHNO AUTOMATION
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
S
serious storage limitations.”
S E RIE
Ultimately, after consulting with a VB1
AG ER Stock Lengths Up To 3 Meters
VOY
student-run focus group and putting
Custom Lengths Up To 6 Meters
the project out for bid, the college
All Steel Profile Rail For High Load Capacity
replaced more than 200 of its old 50mm Wide Steel Reinforced Belt For Heavy Loads
desks with a set of Arlink worksta-
tions from industrial workbench and
cabinet manufacturer Lista Interna- VISIT OUR DOWNLOAD 3D MODELS
tional Corp. WEBSITE REQUEST FREE CATALOGS
at www.technoautomation.com
According to Rich Preiss, the school’s
director of laboratories, the school GANTRY TABLE
chose the Arlink workbenches because XY or XYZ 12 Series
they were rugged, functional and aes- Glue Dispensing
thetically pleasing. Assembly
Lambla adds that Lista was also very Inspection
responsive in terms of meeting the Pick & Place
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 AFFORDABLE
QUALITY
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
Techno Inc. 1-800-819-3366
SINCE 1986
with the Arlink desks. Linear Motion Systems www.technoautomation.com
“We needed somebody who could
See us at ATExpo, Booth 541
www.assemblymag.com August 2009 / ASSE M B LY 21
ASSEMBLY Medical Device Assembly

Better One or
Better Two?
Ophthalmic device

manufacturers keep an eye on
new technology.
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
 By Austin Weber
Senior Editor
22 ASSEMBLY / August 2009 www.assemblymag.com
A
s 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.
 “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, A wide variety of diagnostic instruments are used by ophthalmologists to examine patients, such as
Germany). However, numerous small slit lamps. Photo courtesy National Eye Institute
start-up companies specialize in niche and scanning laser tomography are imaging devices called OCT (optical
segments, such as cataract, corneal or both giving increasingly sharper reso- coherence tomography) that allow us to
refractive surgery. lution of the microscopic structures of create microscopic images of structures
No matter the size of the company, the eye, allowing for a more detailed inside the eye that were never before
ophthalmic manufacturers are focusing view of pathology. visible,” adds John Hovanesian, M.D.,
their efforts on making surgical proce- “This has also allowed us to an ophthalmologist at Harvard Eye
dures faster, easier, more accurate and visualize the relationship between the Associates (Laguna Hills, CA) and
more affordable. There’s also a growing different regions of the eye in a way a clinical instructor at UCLA’s Jules
trend toward drug-device combination we have never been able to before, Stein Eye Institute (Los Angeles). “This
products. without having to resort to intravenous greatly aids in diagnosis of conditions
dye injection,” explains Shatz. “More like diabetic eye problems, eye tumors
Diagnostic Tools doctors are adopting technology that and macular degeneration.”
Traditionally, the ophthalmic indus- allows us to image the back of the eye An OCT allows an ophthalmologist
try is divided into two main segments: without the need for dilation.” to construct three-dimensional images
diagnostic instruments and surgical “We now have incredibly precise of living eye tissue with better resolution
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- The human eye is a complex, delicate organ. Common back-of-the-eye diseases include
age-related macular degeneration and glaucoma. Illustration courtesy American
ogist at the Woolfson Eye Institute
Academy of Ophthalmology
(Atlanta). “High-speed ultrasound
www.assemblymag.com August 2009 / ASSE M B LY 23
Medical Device Assembly
than a traditional MRI scan. the world’s first noninva-
Better yet, the procedure sive early detection device
can be performed in a for cataracts, the leading
doctor’s office instead of a cause of vision loss world-
hospital. wide. The new device is
Today’s new breed of based on a laser light tech-
diagnostic instruments use nique called dynamic light
state-of-the-art technology scattering (DLS).
to objectively measure and It was initially devel-
quantify vision disorders. oped to analyze the
For instance, engineers at growth of protein crystals
Optos Inc. (Marlborough, in a zero-gravity space
MA) recently developed environment. The table-
a new type of imaging top DLS device is used
device that provides an to detect the earliest dam-
ultra-widefield view age to lens proteins, trig-
of the retina. It allows gering an early warning
ophthalmologists to see This telescopic implant is 4 millimeters long and contains two wide-angle glass for cataract formation and
lenses. It is designed to treat age-related macular degeneration. Photo courtesy
more than 80 percent of VisionCare Ophthlamic Technologies Inc. blindness.
the retina, compared to a “Much of the work [in
traditional camera that provides a much Researchers at the National Eye Insti- the diagnostic instrument field] is going
narrower view—about 11 percent. The tute (Bethesda, MD) and the National into finding ways to treat presbyopia to
device uses scanning coherent laser Aeronautics and Space Administration enable people to get rid of their reading
light rather than full spectrum white (NASA, Washington, DC) recently glasses,” says James Ohneck, CEO of
light that’s typically used by cameras adapted a compact fiber-optic probe Oculatek Inc. (Cleveland). The start-up
and other forms of ophthalmoscopy. developed for the space program into company has developed a transscleral

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24 ASSEMBLY / August 2009 www.assemblymag.com

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
asb08094dymax.indd 1
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
See us at ATExpo, Booth 1233
www.assemblymag.com August 2009 / ASSE
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
B LY 25
7/14/09M10:20:55 AM
Medical Device Assembly

An OCT allows ophthalmologists to construct three-dimensional images of

living eye tissue with better resolution than a traditional MRI scan. This fiber-optic probe uses NASA-developed technology to detect
Photo courtesy Carl Zeiss Meditec AG cataracts. Photo courtesy National Eye Institute

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.

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asb08094weiss.indd 7/6/09 3:09:13 PM
 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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results in a more compact package.
cka
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This instrument is used for cataract surgery. It
features a high-definition touchscreen display
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The latest trend in IOLs is
toward corrective, foldable lenses FEATURES
that are structurally designed to Advanced Auto Set-up
minimize secondary cataracts from Auto Calibration
occurring. Most companies developing Vivid Full Color Display
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intraocular implants are focusing their
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efforts on devices that treat back-of-
the-eye diseases, such as glaucoma and
The latest addition to the Sentinel
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ins r men s
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
AT
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surgical procedure is painless and
only takes about 20 minutes. Some
ophthalmologists are recommending 513.367.6699
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the procedure as an alternative to the
more controversial Lasik treatment. providin g w or l d- c l as s l e a k t e s t an d
In addition, engineers and doctors as s em bl y v e r i f i c at i on s ol u t i on s
are currently developing polymeric
drug delivery devices that are implanted sal es@cincinnati-test.com cincinnati-test.com
at the time of cataract surgery along
See us at ATExpo, Booth 635
www.assemblymag.com August 2009 / ASSE M B LY 27
Capital Spending Medical Device Assembly
Ophthalmic devices, such as intraocular lenses, are typically assembled in clean rooms.
Photo courtesy Carl Zeiss Meditec AG
for back-of-the-eye applications,” he
explains. “We are also in very early
COLOR-CODED development discussions with potential
CONNECTORS partners who are interested in utilizing
SIMPLIFY FIELD our technology to create IOLs capable
of drug delivery.”
INSTALLATION. Implantable intraocular lenses pose
numerous manufacturing challenges.
Forget paging through
“The main challenge for us is to make a
pinout diagrams at every
installation. TURCK has
device small enough to be inserted with
added color-coded and the lens, yet big enough to hold enough
clearly labeled pinouts to drug,” says Klein. “There are also
the company's wide variety technical challenges to overcome with
of connectors, so installation existing injection molding techniques
is faster and easier. when making devices this small.”
For instance, lenses must be extreme-
Connectors are available for: ly thin to be flexible and comfortable to
t
%FWJDF/FU™ patients. Klein believes the ophthalmic
t
'06/%"5*0/
mFMECVT™
device industry may be able to adapt
existing semiconductor manufacturing
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® get smaller.
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“[However], ophthalmic implantable
t

4UBOEBSE
.
DPOOFDUPST
BSF
devices must be as long-acting as
BMTP
BWBJMBCMF 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.”
Call us with your next application: “The goal at the moment is to achieve
1-800-544-7769 better efficacy with less invasive proce-
email: turckusa@turck.com dures,” notes Paul Ashton, M.D., presi-
www.turck.com 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
© 2009 TURCK, Inc. dry age-related macular degeneration
(AMD) and diabetic retinopathy.
See us at ATExpo, Booth 615
28 ASSEMBLY / August 2009 www.assemblymag.com
“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
is a little like having a cataract opera- Your Global Distributor of Adhesives,
tion,” says Ashton. Sealants and Assembly Equipment
The next step in the evolution of this
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a needle,” says Ashton. “This allows it & Accessories
to be injected directly into the eye in Dispensing Equipment
an office visit [as opposed to outpatient
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surgery, with fewer complications]. The
procedure is also far cheaper.”
According to Ashton, future
ophthalmic devices will continue to
get smaller and more sophisticated. ellsworth.com/Assembly.html
“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 ISO 9001:2000
to a disease or tell a physician if they are
about to run out [of a drug].” Visit our website and chat with the Glue DoctorTM about an adhesive assembly solution.
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and drug-device hybrids, another new
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mologists is the artificial retina. “This
device has given hope to patients asb08094ells.indd
have lost vision from disabling retinal
who
Technifor Direct Part Marking
1 7/14/09 1:14:28 PM

diseases such as macular degeneration,”

says Shatz. “While the resolution is and Traceability
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 Micro-Percussion Scribing Laser Marking
California (Los Angeles). It consists
of an array of 60 electrodes that are
attached to the retina. The electrodes Contact us for in-plant
conduct information acquired from an analysis and demos.
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 Tag Marking 2D Coding
model will be available within the next & Reading
few years. A 800-394-9101
Technifor, Inc.
For reprints of this article, Tel. 704-525-5230
Fax. 704-525-5240
www.technifor.com
please contact Cindy Williams
at williamsc@bnpmedia.com e-mail: tfinc@usa.technifor.com UID Compliant
or 610-436-4220 ext. 8516.
www.assemblymag.com August 2009 / ASSE M B LY 29
ASSEMBLY Parts Marking
When All You
Need Is a Dot
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.
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
 By John Keating
Business Unit Manager, ITW DYKEM
Olathe, KS
and
Claude Bergeron
Product Line Manager, EFD Inc.
East Providence, RI
30 ASSEMBLY / August 2009 www.assemblymag.com
M
anufacturers 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
with numbers,
letters or some other
i d e n t i fi e r, s o m e
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.
Clogging can be
minimized by using
a low-volume, low-
pressure spray
system.
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
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 This spray valve has a dual-ported fluid head. A programmable air
delay after each shot keeps the nozzle clean and reduces clogging
thick, heavy spray mark that and maintenance. Photo courtesy EFD Inc.
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 This spray marking system uses a motorized gear pump to keep
picked up by visual scanning pigmented inks in suspension and constantly circulating through
systems. the valve. Illustration courtesy EFD Inc.
www.assemblymag.com August 2009 / ASSE M B LY 31
Parts Marking
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

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
Both issues—clogging and a recirculating pump that keeps the
separation—can be prevented with marking fluid moving so the pigment
an LVLP spray marking system remains in suspension.
with a double-ported fluid head and EFD’s new 781RC recirculating
Ergonomic Workplaces and Assembly Lines
Conductix-Wampfler has one critical mission:
To supply manufacturers with a wide range
of safe, ergonomic overhead energy supply
and material handling solutions for assembly
Electric & Air Supply lines and work cells. Our custom systems
Systems include the right mix of tool transporters,
tool balancers, and overhead electric/air
supply systems to keep your assembly lines
running at peak efficiency. Our rugged, low
maintenance products are time-tested in
demanding environments and backed by a
Equipment Carriers worldwide sales and service network.
When comparing contact and
noncontact marking systems, engineers
should consider these factors:
䡵 marking speed.
䡵 the cost of the marking fluid and
need to maintain inventory (individual
stain bottles and applicators vs. less
expensive bulk bottles).
䡵 the need to regularly monitor the
system to ensure ink is in the bottle vs.
using a tank that can be filled once at
the start of a shift.
䡵 time needed to change ink bottles or
refill a tank and whether the line must
be shut down to do this.
䡵 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
For reprints of this article,
please contact Cindy Williams
at williamsc@bnpmedia.com
or 610-436-4220 ext. 8516.

Contact us today with your system

ASSEMBLY ONLINE
requirements! For more information on parts marking,
Tool Transporters visit www.assemblymag.com to read these
Balancers articles:
䡲 On Your Mark.
Conductix-Wampfler | 8091 Production Drive | Florence, KY 41042 䡲 Rubber Stamping Assembly.
Tel: (800) 326 2899 | Fax: (859) 814 2110 info.us@conductix.com | www.conductix.com
䡲 The Expanded Reach of Laser Marking.
See us at ATExpo, Booths 727 & 1421
32 ASSEMBLY / August 2009 www.assemblymag.com
 Assemble it faster, better, for less.
Find cost saving new products, technologies, and ideas at ATExpo.

EXHIBITION & CONFERENCE

September 22–24, 2009
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At Assembly Technology Expo, you can see, test, and compare the complete spectrum
of assembly products, technologies, and processes. ATExpo’s hands-on product
demonstrations and conference sessions provide the solutions you need to
improve your process, cut costs, and protect your bottom line.

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ASSEMBLY Electronics Assembly
Riding the
Mini Wave
Automated selective soldering
S
elective soldering with a
miniature wave or fountain
technology saves EMS of molten solder offers many
advantages compared with
facilities time and money. 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
Molten solder is pumped through this small the solder fountain moves beneath it
nozzle to create a fountain with a directional or to solder pins, rows and connectors.
spherical shape. 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
 By Reed Gaither nearby components and pads.
CEO Other systems hold the fountain
RPS Automation LLC stationary and move the PCB. Often
Spokane Valley, WA referred to as “top-side gantry” systems,
rgaither@rpsautomation.com these machines can position boards
34 ASSEMBLY / August 2009 www.assemblymag.com
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
“We have
decreased the cost
of labor by at least
half.”—Todd King,
E.I. Microcircuits
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.
 “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
Soldering nozzles come in various shapes and sizes to suit
cost of labor by at least half [using specific applications.
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
Programmability is particularly important for any machine in
point-to-point when needed, or a high-mix assembly environment. Soldering software should
drag soldering and a mini wave for provide a simple user interface and use scanned images or
some larger areas if needed. The Gerber data.
www.assemblymag.com August 2009 / ASSE M B LY 35
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.
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.
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.
36 ASSEMBLY / August 2009 www.assemblymag.com
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
For reprints of this article,
please contact Cindy Williams
at williamsc@bnpmedia.com
or 610-436-4220 ext. 8516.
ASSEMBLY ONLINE
For 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.
ASSEMBLY ASSEMBLY EVENTS

Don’t Miss
the Big Show
Find the tools your company

D
espite the economic hard times,
assemblers in the United States
needs to succeed at ATExpo will still spend more than
$2.5 billion on new assembly
2009. 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
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 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.
 By Adam Cort
Senior Editor
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
www.assemblymag.com August 2009 / ASSE M B LY 37
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
 ASSEMBLY EVENTS

Prepare for the Rebound

at the Assembly Conference
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 principal and expert on supply chain management at Archstone
a business in a recovering economy. The automation track will Consulting, will give a pair of presentations titled “North
feature speakers such as Mikron Corp.’s Jim Mueller, who will America: the New Low Cost Manufacturer” and “Planning
explain how designing a new product with assembly in mind for the Rebound.” In these sessions, attendees will learn how
can reduce costs. companies can position themselves to take advantage of the
On Wednesday, the conference continues with three more latest trends in manufacturing.
tracks: “Technology for Profitable Assembly,” “Robots and Finally, the conference will end on Thursday with a pair
Vision,” and “Preparing for the Economic Recovery.” of workshops: “Reducing Part Counts and Product Costs
The session on profitable assembly will begin with Through Compliant Design” and “Lean Workshop:
presentations on resistance welding, crimp quality verification, Operating System Design.”
and press fits and process monitoring. In the afternoon, the track Chairing the session on complaint design will be Sridhar Kota,
continues with a panel discussion on how even small companies Ph.D., a professor of mechanical engineering at the University
can benefit from robotics. There will also be a presentation of Michigan. Leading the workshop on lean manufacturing will
by Denise Coogan, manager for safety and environmental be Matt Zayko of the Lean Transformations Group.
compliance at Subaru of Indiana Automotive Inc., on how her Individual sessions are about an hour long, and will begin
plant has cut the amount of solid waste it generates to zero. at 9 a.m. and end at 3 p.m. on Tuesday and Wednesday.
The track on robots and vision will include sessions on robots Thursday workshops will begin at 9 a.m. and finish at noon.
and the “green” economy, collaborative robots working in close For more information, including session abstracts and a
proximity to people, and how to employ machine vision to complete conference schedule, go to www.devicelink.com/
improve your bottom line. In the afternoon, Dr. John Kamauff, a expo/atexpo09/conference.html.

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-
38 ASSEMBLY / August 2009 www.assemblymag.com
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
upper Midwest—Illinois, Wisconsin,
Michigan, Indiana and Ohio—are
Join Us at the Lean Factory!
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 Sponsored by the Lean Factory and infrastructure; and tools that can be
and covers economically sound and Group, comprised of Bosch Rexroth used to create a visual factory.
nonpolluting manufacturing processes Corp., Orgatex Americas LLC, Attendees will see presentations
that conserve energy and natural Leonardo Group Americas, and Omron on lean manufacturing; interact with
resources. STI, this year’s Lean Factory exhibit experts in the field; and take part in the
Products and services featured will will demonstrate the importance of a step-by-step creation of the perfect lean
include solar and wind power systems, data-driven approach to line design; production environment, culminating
recyclable and reusable packaging, the need to create an environment that in an actual build demonstration on an
energy management software, and supports lean with the right equipment optimum lean line.
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
See us at ATExpo, Booth 1214
www.assemblymag.com August 2009 / ASSE M B LY 39
 Products
Grippers Certified for
Clean Room Use
Grippers 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
Reactor H-VR Offers
Adjustable Ratio Settings
The 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
40 ASSEMBLY / August 2009 www.assemblymag.com
Painting Robot Is Compact, Flexible
The 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
Crimper Accommodates Multiple Stations
The 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.
Schleuniger
www.schleuniger-na.com
603-668-8117
Test, Monitor System Easy to Configure
The 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 Instruments
www.sciemetric.com
866-900-7054
Leak Detector
Minimizes Operator Error
MS-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 Detection
www.vicleakdetection.com
631-737-0900
Belt Conveyors Are
Sturdier, Easy to Service
TB 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.
Montech
www.montech.com
Robot Has ‘Zero’ Footprint
The 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 Clear
The 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 Motion
The 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 America
www.keyence.com/vw
Posts, Pins Facilitate
Light Assembly
New post-and-pin combination includes pins
molded in white polycarbonate material and
posts in various lengths molded in white
www.assemblymag.com August 2009 / ASSE M B LY 41
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 Materials
The 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.
Scheugenpflug
www.scheugenpflug.de
Mobile Workstation
Safeguards Laptops
This 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
 Products

station provides a workspace that is 42 inches kit includes all necessary mounting hardware, Sensors Combine Accuracy, Value
wide, 26 inches deep and 38 inches high. Cus- making installation as simple as tightening The OD Value line of optical displacement
tom dimensions are also available. down the bolts. sensors provides high-accuracy performance
Creform Corp. GAM at a competitive price with a variety of inter-
www.creform.com www.gamweb.com face capabilities for use in a wide range of
800-839-8823 888-GAM-7117

Slides Available in Five Days Rails Provide Accuracy,

Customized LSK linear slide kits are now Cost Savings
available in just five days, dramatically cutting LFS 12 Series low-profile linear rails and car-
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

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
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.
SICK
www.sickusa.com

268 METRIC HINGES

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Email: leaktest@atequsa.com
Website: www.ateq.com

See us at ATExpo, Booth 1238

42 ASSEMBLY / August 2009 www.assemblymag.com
Asb02084AMSP.indd 1 1/3/08 9:17:55 AM
 Dispense, Spray System
Includes Tilt Feature
The 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
INDUSTRIAL
ROBOTS
SR-SERIES small cartesian robots are suitable for
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Pipette Enables three sizes and offers positive displacement
Contaminate-Free Dispensing dispensing in a range of volumes from 0.01 to
The Stepper pipette enables contaminate-free 1.00 milliliter. Each pipette can dispense up to
dispensing in a simple-to-operate, handheld 100 shots per fill.
system. The dispenser incorporates a light- Tridak
weight, ergonomic design and is constructed www.tridak.com
of aluminum for maximum durability. Users 860-626-6700
Readers Fill Multiple Niches
HS-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
can dispense a variety of low- to medium- on printed black-and-white labels. The HS-2D
viscosity materials. The pipette is available in reader is a higher performance model that can
Custom Adhesive
Encapsulant Packaging
&
Specializing in packaging adhesives and encapsulants in convenient
syringe and cartridge systems, ideal of Electronic assembly.
• Premixed and frozen two component
• Difficult to package one component resins
• Air-free syringes and cartridges for automated
X-Y-Z dispensing systems
• Maximum 5-day lead time from receipt of materials
• Custom mixing and blending per your specifications
For product
samples, please
call 866-322-8322
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LY 43 3:45:41 PM
 Products

be used to decode both linear barcodes and
2D symbols in a wide range of environments,
including clean rooms.
Microscan
www.microscan.com
Wire Stripper Collects
Insulation Residue
The 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 in the automotive and commercial vehicle
wires during stripping. industries.
Eraser Inc. Dürr Ecoclean
www.eraser.com www.durr-ecoclean.com
315-454-3237
TFT Systems Available
Robotic Cleaner with Hollow Shafts
Handles Heavier Loads Torque Functional Test (TFT) systems pro-
Ecoclean flexible robotic cleaners can now viding monitored and measured amounts of
accommodate industrial parts weighing up to 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

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

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components are being processed. The TFTs employ servomotors, pre- resistant to motor oils,
cision position sensing feedback technology and extremely accurate transmission fluids
torque transducers to produce controlled torque inputs and feedback and most other work-
monitoring. related compounds,
Promess Inc. such as greases and
www.promessinc.com cutting fluids. The
810-229-9334 stains can be applied
by brushing, spraying
Tubing Good for Appliances, Food Industry or dipping. Dry time is
Ethelplas tubing is extruded from nontoxic, 100 percent virgin linear less than 15 minutes.
low-density Polyethylene resin for use in commercial and household ITW
appliances, the food industry and laboratory testing equipment. It www.dymon.com
provides good resistance to chemicals and is nonconductive. The tub- 800-443-9536
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, Portable

The 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 Applications include:
high speeds, making it small linear slides, medical
equipment, instrumentation, • High Energy Capacity in
ideal for use in scan-
packaging, material handling, Minimum Sized Packages
ning mid- to large-
sized objects, such rotary actuators and more • Proven Designs & Performance
as molds, stampings • Ideal for Mounting in
and sheet metal. The Confined Spaces
probes are portable and can be easily integrated with a coordinate mea- • Self-Compensating
suring machine (CMM) arm. & Adjustable Models
Main
Laser Design Inc. Catalog
www.laserdesign.com Available
Online
952-884-9648

Stains Are Environmentally Friendly Farmington Hills, MI 48335

tel: 800-521-3320 fax: 248-476-2470
DYKEM water-based stains can be used to permanently color code e-mail: shocks@acecontrols.com
springs, small parts, tools and finished assemblies. The stains produce acecontrols.com
little odor and emit few VOC’s. Their non-xylene based formulation is

asb08094ace.indd 1 6/25/09 1:13:33 PM

See us at ATExpo, Booth 515

asb05094janome.indd 1 4/6/09 2:28:57 PM
www.assemblymag.com August 2009 / ASSE M B LY 45
 Products
Clamps Combine
Accuracy, Ease of Use
Zero 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, Economical
The Arlink 7000 workbench is a cost-effective,
easily assembled, general-purpose workbench
capable of supporting up to 1,000 pounds. It is
available with a range of work surfaces, includ-
ing plastic laminate, static dissipative laminate
and butcher block. Leg extenders for extra
Classified
Need Work Benches
?
www.1proline.com
In Stock
For information on Classified
Advertising call Vito Laudati:
630-694-4018
46 ASSEMBLY / August 2009 www.assemblymag.com
wafer without leaving a mark, even when han-
dling wafers that are smaller than the contact
surface of the gripper. The gripper can also be
safely used in a clean room environment.
Schmalz Inc.
www.vacuworld.comasb0809
Gantries Provide Speed, Precision
height, 5-inch-diameter casters and a choice of AGS15000 series Cartesian gantries incorpo-
hanging drawers are also available. The benches rate a planar design that minimizes dynamic
come in light gray, bright blue or sand. pitch errors for use in a wide range of precision
Lista International Corp. applications, including stencil cutting, fuel
www.listaintl.com
800-722-3020
Gripper Configured for
Solar Production
The new SWG vacuum gripper is configured
for precise, gentle handling of highly sensitive
wafers and solar cells. It provides a cycle time
of 1 second and grips the entire surface of the
cell manufacture, high-speed pick-and-place
systems, automated assembly, dispensing and
high-accuracy inspection. The system’s BLM
and BLMH series brushless linear servomo-
tors provide speeds of up to 3 mps and 5G
acceleration.
Aerotech
www.aerotech.com
412-963-7470
847-534-1000
LEAN CELL SPECIALISTS
⽧ CUSTOM ASSEMBLY EQUIPMENT
⽧ QUALITY CONTROL SYSTEMS
⽧ SPECIAL MACHINERY
⽧ SPECIAL FIXTURES
⽧ PRECISION CNC MACHINING
www.krygierdesign.com
www.assemblymag.com
 Advertisers Index
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
This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.
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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www.assemblymag.com August 2009 / ASSE M B LY 47

 Leading
Lean
Jamie Flinchbaugh
Partner
The Lean Learning Center
Novi, MI
Close the Knowledge Gap
I
n 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
Close knowledge gaps before
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 first is, what do I need to learn
more about? Another way to phrase
it would be, what specifically 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
48 ASSEMBLY / August 2009 www.assemblymag.com
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.
closing performance gaps.
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 filters, 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.
Email Jamie with comments via
jamie@leanlearningcenter.com.
For his recommended books
see tinyurl.com/leadinglean
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