Optimation Blog

Evaluation of Process and Product Variability

Posted by Robert Hopkins on Aug 7, 2019 7:30:00 AM

At one point, Kodak continuously evaluated over two hundred thousand process and product parameters for all production orders in the worldwide film supply chain. The parameters being evaluated included: key process parameters, such as chemical reactor feed flows and temperatures; product release parameters, such as number of defects in a 10,000 ft master roll of coated film, and the condition of critical process components, such as pump vibration level, heat exchanger approach temperatures, motor current draws and control valve positions. Automatic alerts are generated to alert maintenance when parts need to be replaced or operations when a product just made needs to be held and not released to downstream operations. How did Kodak accomplish this level of aggressive monitoring in a global supply chain with flexible manufacturing systems and thousands of product recipes? In short, the answer is Process Monitor.

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Topics: Quality, Process Monitor, IT, IIoT

Web Handling FAQ

Posted by Pete Sherer on Jul 18, 2019 1:21:05 PM

One of our core competencies at Optimation is in the development, design, fabrication and improvement of web-based, or roll-to-roll, processes. Optimation owns and operates a web development laboratory – we call it the Media Conveyance Facility (MCF). Many things you use on a regular basis are produced on a web, from aluminum foil to the thin glass used in cell phones.

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Topics: Mechanical and Process Services, Manufacturing, Equipment, web handling

Capital Project Investing:  How to turn Complexity and Risk into Success

Posted by Pete Sherer on Jul 2, 2019 8:27:20 AM

In business, it’s been said, “you need to spend money to make money.” This axiom certainly applies to capital investing, where market demands can be exploited with increased production through the careful implementation of new equipment.

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Topics: Mechanical and Process Services, Purchasing, Business, Skid Systems, Upgrades, Project Management, Engineering Services

The Best Thing You Can Do Before Going Out to Bid

Posted by Wendy Smith on Jun 24, 2019 10:07:06 AM

One of the most important factors for a successful project is being able to specify the requirements up front. Many times, the customer doesn’t know exactly what he needs. More preliminary engineering is required to get the project requirements specific enough for suppliers to offer a fixed price bid for the project. But often, clients don’t realize they need to budget for this and therefore don’t want to pay for this service.

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Topics: Purchasing, Project Management

Using Process Monitor to Track Roller Traction in a Flexible Web Machine

Posted by Pete Sherer on Jun 17, 2019 10:22:08 AM

Recently a team of Optimation’s web conveyance experts teamed up with a pair of Eastman Kodak’s IT experts to create a means to demonstrate the power of applying a process monitoring tool to a known but illusive problem.  The demonstration involved using Optimation’s Thin Web Rewinder, one of the pilot machines located in our Media Conveyance Facility, and Kodak’ proprietary Process Monitor software.  We elected to use roller traction as the parameter of interest, because it is a functional attribute that is subtle, making it challenging to measure and status over time.

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Topics: Quality, web handling, Process Monitor, IT, IIoT

Robots Come of Age

Posted by Bill Pollock on Jun 5, 2019 10:11:01 AM

Robots are beginning to show up everywhere. Of all the amazing technical developments that are part of Industry 4.0, the fastest growing sector is robotics. By 2020, over $100 billion a year will be invested in robots and this amount is projected to double every two years. 

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Topics: Robotics, IIoT

New York’s Manufacturing Legacy in the Fourth Industrial Revolution

Posted by Bill Pollock on May 30, 2019 10:05:49 AM

I recently attended the New York State Manufacturing Conference in Troy, hosted by the CATS center at RPI.  The focus of the conference was advancing technology and manufacturing in New York.  I had the opportunity to be part of the conference and gave a talk titled, “Building on New York’s Manufacturing Legacy in the Fourth Industrial Revolution – Industry 4.0.”  Industry 4.0 is an amazing step forward in technology and defines an exciting era for manufacturing which began just this decade.

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Topics: Manufacturing, Trends, IIoT

Equipment and Environmental Safety

Posted by Steve Beyer on May 29, 2019 8:00:00 AM

Following up on my last blog post, I continue the discussion acknowledging that safety is not trivial or to be taken for granted. It is multi-level and is tied to the long-term success of each project and every client. The first three levels of safety covered were operator, consumer/customer, and product/process.  This post covers the remaining two: equipment and environment.

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Topics: Manufacturing, Safety, Equipment

The Many Levels of Safety

Posted by Steve Beyer on May 22, 2019 8:00:00 AM

Safety is not trivial or to be taken for granted. It comes in multiple varieties, is multi-level, and is inherently tied to the long-term success of each project and every client. These levels of safety include operator, consumer/customer, product/process, equipment and environment. Each level requires and receives due diligence, understanding the unique parameters of the project and the measures of success that bound the work. Several of these levels will be described further here, highlighting the value delivered to the project in the safe and efficient process and outcome of the work. The remaining safety levels will be discussed in a subsequent post.

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Topics: Manufacturing, Safety, Automation, System Integration

New York’s Manufacturing Legacy and Its Manufacturing Future

Posted by Bill Pollock on May 20, 2019 7:15:00 AM

I recently attended the New York State Manufacturing Conference hosted by the Center for Automation Technologies and Systems (CATS) center at Rensselaer. It was a spirted event attended by participants from a variety of individuals and companies whose primary focus was promoting and advancing technology and manufacturing in New York.  Robots and cobots were everywhere.  More than 70 organizations were represented from industry, academia, economic development and technology centers. 

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Topics: Manufacturing, Trends, Robotics, IIoT

Welcome to the Optimation Blog

Tips, tricks and trends

The goal of this blog is to be helpful to readers by providing useful information about applications in industrial engineering, design and skilled trades, as well as industry knowledge. We're passionate about manufacturing in the United States. We have a little fun with it too.  

 

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