Automated Assembly

9 to 11 a.m.

Implementing Automation After Making Lean Improvements

Tom Lawton, Advent Design

Many times, a company automates part of a production process without considering the effect on the entire process flow. Implementing automation to reduce cycle time and increase output without considering the effects on upstream and downstream operations can lock in poor material flow. In this seminar, attendees will learn how to develop automated manufacturing systems that enhance lean manufacturing principals and promote product flow.

Materials Joining

9 to 11:30 a.m.

Micro-Laser Processing

Kevin Ely, Edison Welding Institute

This course will cover low-power laser processing, beginning with an overview of laser physics, the use and role of optics, the differences between CO2 and ND: YAG welding, including continuous wave and pulsed processing. You will learn how power, pulse width and focal length affect the weld zone. Common weld defects, and steps to reduce or eliminate them, will also be discussed.

Materials Joining

9 to 11:30 a.m.

Adhesives, Potting and Encapsulation

Dr. George Ritter, Edison Welding Institute

This workshop outlines the fundamental concepts of polymeric materials. Applications include assembly adhesives, conductive adhesives, encapsulants, potting agents, thermally conductive materials and resins found in circuit board materials. Topics include polymer basics, resin types, curing mechanisms, thermal issues, and comparisons of material types and performance. Testing protocols will also be discussed. Participants are encouraged to bring applications issues for discussion or to arrange a meeting with the instructor to discuss your application privately.

Lean Manufacturing

9 a.m. to 5 p.m.

Lean Production—Less is More

Pascal Dennis and Eric Hager, Lean Productivity Systems

This workshop introduces the basic concepts and tools of lean production. Manufacturing simulations will allow attendees to understand this strategy’s effect on productivity, quality, lead-time and cost. They will also learn the difference between lean production and traditional mass production.

Automated Assembly

1 to 3 p.m.

Negotiating the Acquisition of Custom Automation Equipment

Richard Bodine, Bodine Assembly and Test Systems

Floyd Moir, Retina Systems

Robert Weskamp, Wes-Tech Inc.

More than ever before, custom builders are treated as commodity suppliers by end users. This has resulted in an unnecessary compromise to the quality of the finished product. In this session, attendees will hear both sides of this dilemma. Industry leaders will provide insight on what changes are needed to stop this cost-destructive cycle to the industry.

Lean Manufacturing

1 to 3 p.m.

Real-Time Data on the Manufacturing Floor in a Lean Manufacturing Environment

Tom Lawton and Frank Garcia, Advent Design

Increasing implementation of lean manufacturing concepts has increased the need for real-time data on the manufacturing floor. As companies implement automation that supports lean manufacturing, lead-times are reduced, and the need for real-time data increases. This session will investigate developing automation for the manufacturing floor that supports lean manufacturing concepts, and integrating enterprise systems to support manufacturing personnel and operations.

Materials Joining

1 to 3:30 p.m.

Small-Scale Resistance Welding

Kevin Ely, Edison Welding Institute

Small-scale resistance welding is a key assembly process. This workshop will provide a thorough understanding of the basic principals of low-force, low-power welds. From these basic principals, the course will cover weld schedule development, including how to develop a lobe curve, key equipment configurations and electrode setup parameters. A key section will compare and contrast power supplies. Monitoring and testing of small-scale welds will also be discussed, with direct reference to wire-to-tab welds, thin sheet welds and the effects of platings.

Tuesday, September 23, 2003

Keynote Address FREE!

9 to 10 a.m.

Six Sigma Is About Success

Jerry Palmer, Caterpillar Inc.

By implementing Design for Six Sigma (DFSS), Caterpillar has achieved breakthroughs in quality and financial performance. In this keynote, Palmer will share Caterpillar’s success with its implementation of DFSS. Caterpillar uses these strategies, statistics and methods in everything from designing to manufacturing to providing business information to internal and external customers.

Lean Manufacturing

9:45 a.m. to 12 p.m.

Implementing Lean Production—It’s Not Luck

Pascal Dennis and Erik Hager, Lean Productivity Systems

Despite the current economic downturn, Toyota has earned profits. What’s its secret? The Toyota system, also know as lean production. But despite Toyota’s extraordinary openness, other manufacturers have had difficulty implementing lean concepts.

Lean Manufacturing

9:45 a.m. to 12 p.m.

The Basics of Just-In-Time and Lean

Ben Schlussel, BMS Associates

This workshop will provide the participants with a solid foundation in the concepts, philosophy and objectives of just-in-time (JIT) and lean manufacturing. Subjects to be covered include waste elimination, continuous process improvement, total quality management, the theory of constraints, and implementation of JIT and lean. A session on developing and involving personnel is also included.

Automated Assembly FREE!

10 to 11 a.m.

Outsourcing Strategies for OEMs

Eric Miscoll, Technology Forecasters Inc.

This presentation will help participants to optimize their outsourcing strategies for today’s challenges. Outsourcing is not a new strategy; yet most operations and supply-chain executives will be surprised that even long-time outsourcers are leaving money on the table or are taking steps that negate optimal communications, flexibility and core competence.

Automated Assembly

10 to 11 a.m.

Advanced In-Process Defect Detection: Application Examples From the Real World

Nathan Sheaff, Sciemetric Instruments

In-process defect detection using signature analysis and sophisticated data management can deliver tremendous return on investment. Signature analysis technology can improve manufacturing quality and repeatability, providing a more thorough understanding of basic manufacturing operations. The ability to collect, analyze and manage process waveform data at various stages in the product assembly process offers tremendous advantages over traditional end-of-line testing. Participants will see actual application examples from manufacturing.

Wire Processing

10 to 11:30 a.m.

Crimp Quality-Data Collection Made Easy

Rob Boyd, Schleuniger Inc.

Quality standards keep getting tighter. And more companies are collecting quality-testing data because of internal policies or customer requirements. Collecting quality-testing data is time-consuming and error-prone. Furthermore, most data collection involves manual data entry, which can also be error-prone. Finally, collecting does not add value to the end product. It simply forces nonvalue-added procedures into the production cycle. This session will describe how crimp quality data collection can be easily implemented into the assembly process.

Materials Joining

10 a.m. to 1 p.m.

Fundamentals of Adhesive Technologies

William F. Harrington, Adhesives and Sealants Newsletter

This course will provide a broad-based foundation in adhesive technology. Content is practical, not theoretical. Attendees will learn what’s important about adhesives, adhesive terminology, adhesive classifications, the basics of good adhesion, and the different adhesives for industrial applications. This course is appropriate for those with limited to moderate knowledge of adhesives and who need or want to learn more about basic concepts.

Manufacturing Management FREE!

1 to 2 p.m.

Global Pricing Model of the EMS Industry

Eric Miscoll, Technology Forecasters Inc.

The single most contentious issue between original equipment manufacturers (OEMs) and contract manufacturers is pricing. Technology Forecasters has developed a model for assisting OEMs to better understand what they should be paying for contract manufacturing in dozens of countries around the world. Participants will learn why most OEMs lack the accurate and detailed total pricing information needed to choose global locations for design, manufacturing, procurement, final assembly, test and after-sale services.

Materials Joining

1 to 5 p.m.

Ultrasonic Welding Processes for Metal and Thermoplastics

Tony DiFinizio and Donald Patten, Stapla Ultrasonics Corp.

This session will cover the fundamental concepts of ultrasonic metal welding and ultrasonic plastic welding. Participants will learn a step-by-step procedure to review metal or thermoplastic bonding applications to establish the feasibility of using ultrasonic welding for assembly.

Lean Manufacturing

1 to 5 p.m.

Sustaining Lean Production— Practical Problem Solving

Pascal Dennis and Erik Hager, Lean Productivity Systems

What is a problem? Why is it important for organizations to have problems? How do we identify and fix the root causes of problems as opposed to providing Band-Aids? How do we harness the knowledge, skill and creativity of our team members? How do we continually improve? Practical problem solving is the key to sustaining lean production. This interactive workshop addresses this core issue of industry and builds on Monday’s “Lean—Less is More” session.

Manufacturing Management

1 to 5 p.m.

Just-In-Time and Lean Operating Principles and Techniques

Ben Schlussel, BMS Associates

This workshop provides a more detailed look at implementing just-in-time (JIT) and lean manufacturing. Subjects to be covered include: planning and scheduling; transaction elimination; production considerations; material logistics; integrating JIT into business processes; metrics and measurements; and implementation considerations.

Automated Assembly

1 to 5 p.m.

Robotics in Assembly

This three-part session will review the various types of robots used in assembly applications. Attendees will also learn about the basics of distributed motion control and how it differs from other architectures. You will see actual before-and-after examples that will help determine if distributed motion control is right for your application.

Part I: Choosing a Robot for Assembly

Jack Justice, Motoman Inc.

Part II: Successful Implementation of Robotics for Small Parts Assembly, Test and Packing

Mark W. Senti, GSMA Systems

Part III: A New Breed of Robot Control

Eric E. Jacobs, Adept Technology Inc.

Lean Manufacturing

1 to 5 p.m.

Workcell Design

William Fillmore, Richard Muther and Associates

This course will discuss waste elimination (not people) through workcells. Participants will learn the benefits of cellular manufacturing and the key elements in workcell design. Also included is critical information on effectively involving employees in cell design.

Materials Joining

2 to 5 p.m.

Adhesive Processing Technology and Selection

William Harrington, Adhesives and Sealants Newsletter

This course concentrates on adhesive use during product assembly. Different methods of adhesive application and bonding processes for various adhesive types will be reviewed. Attendees will also learn about equipment for labor-intensive and machine-intensive operations; testing protocol; and the criteria for choosing adhesive for a particular assembly operation.

WEDNESday, September 24, 2003

Materials Joining

9:45 a.m. to 12 p.m.

Fuel Cell Assembly

Part I will review the primary issues and challenges of brazing fuel cell materials, including stainless steels, high-temperature nickel-based alloys, and ceramic (solid oxide) materials. This talk is targeted at those currently brazing or interested in brazing fuel cell components. Part II discusses the importance of adhesives and sealants in fuel cell development and reliability. All fuel cell systems include several forms of heat exchangers. The combinations of materials, operating environments, and anticipated high production volumes demand that advanced manufacturing processes be considered. Part III will discuss laser welding as a prime candidate for fuel cell heat exchanger assembly.

Part I: Brazing of Fuel Cell Materials

Peter Hall, Edison Welding Institute

Part II: Adhesive Bonding for Harsh Environments

George W. Ritter, PhD, Edison Welding Institute

Part III: Laser Welding of Heat Exchangers

Stan Ream, Edison Welding Institute

Manufacturing Management FREE!

10 to 11 a.m.

Spotting a Troubled Situation—Reducing Underperformance

Robert Morris, Daniel Dooley, Bob Wanat and Jim Ross, Morris Anderson and Associates Ltd.

In today’s troubled economy, even historically sound companies are struggling to stay alive as they face reduced sales volume, increased pricing pressures, rising fixed costs, high levels of debt and difficulties raising new capital. Spotting underperformance is key to survival. This session will discuss ways to spot and reduce underperformance in a manufacturing facility.

Wire Processing

10 to 11:30 a.m.

The IPC/WHMA A-620 Overview

Rodger Diehl, Tyco Electronics

Developing the IPC/WHMA-A-620 standard has been a long and arduous process, which has lasted more than 3 years. This presentation will break down the information contained within the standard and provide an understanding of how the document was developed, how it is intended to be used, the terminology that is peculiar to this standard, and the various inspection criteria found throughout this document.

Lean Manufacturing

10 a.m. to 12 p.m.

Design for Manufacture and Assembly Using Geometric Dimensioning and Tolerancing

Mike Lewis, Lockheed Martin

This course will show how a product’s functional requirements are converted into designs that have the highest level of functionality and manufacturability, but at the lowest cost. Geometric dimensioning and tolerancing will be demonstrated as the only tool that can convey functionality, design intent, fixturing requirements and verification techniques.

Materials Joining

10 a.m. to 1 p.m.

Adhesive Forum

This five-part program is designed to educate end-users, designers and specifiers about the benefits of using adhesives and sealants instead of fasteners for assembly and structural applications.

Part I: Bonding of Low Surface Energy Plastics Without Surface Preparation

Dr. William Driscoll, 3M Industrial Adhesives & Tape Division Technical Service

Part II: Multiple Functions of Specialty Tapes: Solving Design Requirements Means Approaching Performance Across Many Dimensions

Paul Boulier, Avery Dennison Specialty Tape Division

Part III: Advances in Acrylic Hybrid Technology: The Next Generation of PSAs

Dr. Graeme Roan, National Starch and Chemical Co.

Part IV: Elastic Bonding Solutions for Dynamic Systems

Scott Henry, Sika Corp.

Part V: Advancements in the Emabond Induction Welding Process for High-Performance Assembly of Demanding Thermoplastic Applications

Steve Chookazian, Ashland Specialty Chemical Co.

Keynote Address FREE!

1 to 2 p.m.

Production Engineering for TPS

Yasuo Tanigawa, Toyota Motor Manufacturing North America

Attendees will learn how Toyota approaches the challenges in planning new process layouts and equipment specifications within the Toyota Production System (TPS). Tanigawa will also address the flexibility required to work successfully with TPS.

Wire Processing

2 to 3:30 p.m.

Process Cost Analysis Seminar

Rodger Diehl and Joe Porter, Tyco Electronics

This seminar will detail methods for improving the assembly process for cables and wire harnesses. The presenters will provide insights on equipment selection and guidance on when to purchase or lease a piece of equipment. The seminar also focuses on providing cable and harness manufacturers with methods to reduce manufacturing costs and improve their return on investment.

Manufacturing Management FREE!

2 to 4 p.m.

Fuel Cell Manufacturing Challenges and Opportunities—Panel Discussion

Moderator: Austin Weber, senior editor, ASSEMBLY magazine

Michael Hudachko, HyRadix Inc.

Mike Krumpelt, Argonne National Laboratory

Stan Ream, Edison Welding Institute

Chris Tynan, Illinois 2H2

Production of fuel cells is predicted to grow at rates exceeding 40 percent per year over the next decade. The market for these trend-setting devices is expected to reach $20 billion by 2010. As a result, hundreds of manufacturers and suppliers are investing millions of dollars in fuel cell development. This lively panel discussion will focus on the mass production issues that need to be addressed before fuel cells become cost-effective for transportation and stationary applications.

Materials Joining

2 to 4:30 p.m.

Answering the Materials Challenge— How Do I Put This Together?

Jim Hutchison, Alcoa Fastening Systems

This session will review lightweight and corrosion-resistant materials used in manufacturing, along with assembly and durability challenges faced by designers. Permanent, removable and reusable mechanical fasteners will also be discussed.

Manufacturing Management

2 to 4 p.m.

World-Class Idea Systems

Dr. Alan Robinson, University of Massachusetts

Most companies are aware that their creative potential far exceeds their creative performance. This session shows a radically different way to manage creativity, which allows companies to realize their creative potential and increase profitability. Participants will learn the six elements of corporate creativity, world-class systems for ideas, how they work and their effect on the bottom line.

Automated Assembly

2 to 5 p.m.

Machine Vision for Assembly

During this three-part presentation, participants will learn how to successfully implement machine vision to solve an application. Lighting, vision equipment and overall system design will be discussed. Participants will also learn how to specify lighting setup for machine vision applications. Various lighting types and techniques will be covered.

Part I: Monitoring Assembly Processes With Machine Vision

Dr. Walt Pastorius, LMI Technologies Inc.

Part II: How to Successfully Implement Machine Vision by Three Perspectives

Mark Sippel, Omron Electronics LLC

Part III: Successful Machine Vision Implementation—The Lighting Perspective

James F. O’Hanley, CCS America Inc.

Lean Manufacturing

2 to 5 p.m.

Application of Design for Six Sigma in the Assembly Industry

Dave Antis Jr. and Reigle Stewart, Uniworld Consulting Inc.

Products designed with the understanding of assembly operations are more apt to be manufactured and meet customer deadlines while maintaining cost targets. This session will show participants how Design for Six Sigma provides the structure for using the appropriate statistical tools in developing new products. Statistical methods are used to design the product and assembly process to optimize the quality and reliability of the end product.

THURSDAY, September 25, 2003

Caterpillar Plant Tour, Aurora, IL

7:30 a.m. to 12 p.m.—Morning Tour

12 to 5 p.m.—Afternoon Tour

Visitors will see first-hand how Caterpillar uses Six Sigma to achieve growth, cost reduction and quality-improvement targets. Visitors will observe the manufacturing, assembly, test and painting of Caterpillar's wheel loaders and hydraulic excavators.