The A3 process is a simple way of getting a problem, an analysis, a corrective action or an action plan written down on a single sheet of large paper, often with the use of graphics. Many manufacturers use it as a powerful lean management tool.

Today, a Silicon Valley startup company called Bloom Energy Corp. unveiled a much-anticipated device called the Bloom Energy Server. The company hopes to install its “little power plant in a box” in millions of homes and neighborhoods around the world, replacing the traditional electric power grid. The concept looks promising, but assembly technology will determine the company's ultimate success . . . or failure.

It takes more than a tall tower and a few huge blades to make a wind turbine go. Hundreds of different components are required, such as gearboxes, generators, shafts, bearings, sensors, motors and controllers.

Robotic ultrasonic welding can be used to join metal or plastic parts. The technology is ideal for some applications, such as welding battery packs, but may not be difficult to justify for other projects.

Demand for wind power is expected to grow rapidly over the next 20 years. However, wind turbine technology needs to evolve. Engineers are currently struggling to make the devices larger, taller, less expensive , more reliable and more efficient.

Traditionally, dedicated ultrasonic welding equipment has been used to assemble only one type of product at a time. But, in today's high-mix, low-volume environment, manufacturers are demanding more flexibility.

Although plastic medical tubing can be joined to itself, it’s often attached to a device, bag or connection. As medical device manufacturers look for alternatives to traditional solvent welding, demand for adhesives is increasing.

Traditionally, plastic medical tubing is manually attached to valves, connectors, catheters, and other devices. But, medical device manufacturers are eager to automate the assembly process. It’s being driven by several trends, such as labor shortages, labor costs and increased levels of quality control.

General Motors Co. started assembling lithium-ion battery packs today at its new $43 million plant in Brownstown Township, MI. The 160,000-square-foot facility is the only one of its kind in the United States operated by a major automaker. Assemblers are building battery packs for the much-anticipated Chevrolet Volt, which will hit the market later this year.