Manufacturing Archives - Page 2 of 6 - Unitherm Insulation Systems

May 24, 2012 by Kendal White

How to Buffer your Supply Chain from the Blow of Natural Disasters

Tsunamis in Japan. Flooding in Thailand. Before 2011, many of us went about our business, unaware of how intricately connected we are in international supply chains. But then, distant shocks caused ripple effects that rocked the entire world.

Such disasters expose the shortcoming of lean manufacturing—although efficient under regular operating conditions, scarcely stocked inventory leads to a greater dependence on a decentralized network and just-in-time delivery.

For the consumer, it’s easy to forget that our goods must travel a complex path as they come into existence and arrive at our local retailer. They, regrettably, don’t appear out of thin air, ready to be purchased the moment we feel the urge to buy them. It’s hard to imagine iPods out of reach because of a far-off shortage of lithium-ion batteries, but that’s the reality of this elaborately entangled ecosystem.

Multinational manufacturers, on the other hand, have a greater appreciation for frailty of the supply chain. Global giants like Honda, Apple, and Intel will tell you—in a split second, Mother Nature can shake even the most carefully crafted supply chain, putting any company’s operational prowess to the test. After the twin tragedies in Asia, economists don’t expect many industries to “return to normal” until 2013.

Still, safeguarding your supply chain and setting up emergency management protocols will lessen the blow if (or when) a natural disaster strikes. Even if you’re not a global giant—catastrophes can hit close to home, knocking out your niche. Just last year, a record number of disastrous tornadoes streaked across the American South.

image from flickr, courtesy of Wesley Fryer

So what can you do about it? It’s a difficult situation because in some respects there’s nothing you can do—weather will rage when it wants to. But here are some tips that will help you prepare ahead of time:

Run best- and worst-case scenarios to test how your organization would handle emergency situations.
Establish a crisis team that is responsible for making and communicating decisions throughout the supply chain.
Diversify suppliers and transportation, which will allow for flexibly in times of disaster recovery.
Maintain detailed processes and procedures and keep them up-to-date with the latest plans.
Review suppliers’ disaster plans on a regular basis and align their plans with your operations.
Monitor threats and trends in your country or region.
Back-up all of your trade-related documents in electronic format and store records offsite.

You can’t control the whims of the Mother Nature, but you can set up supply chain strategies to handle shortages and market fluctuations. Many multinational manufacturers took a hit in 2011—how likely would their recovery have been without tactical and predetermined emergency management protocols? For proof that such protocols make post-disaster situations passable, look at the iPods and Accords all around us today.

May 22, 2012 by Kendal White

Promoting STEM Education in America

image from teach.com

It’s a tough truth. In math and science, American students rank far below their international peers. So as the world accelerates towards technologically advanced everything, will American innovation fall behind?

We created the Colt revolver. The vacuum cleaner. The hearing aid. The light switch. The jukebox. The oil well. The metal detector, the microwave oven, the AC motor, the sewing machine. We developed Morse Code and cable TV. We implanted the first artificial heart. We built the first computer and set up the Internet. We flew the first airplane and landed on the moon.

So what happened? Probably a combination of things. According to the National Science Foundation (NSF), “During the economic turbulence of the 1970s and 1980s, it became clear that industry and academia had become estranged from each other. Manufacturing-related scientific research at the universities wasn’t making it out into the real world quickly enough, if at all.”

Furthermore, NSF explains that to succeed in today’s hi-tech society, “students need to develop their capabilities in STEM (science, technology, engineering, and math) to levels much beyond what was considered acceptable in the past.”

Some call it the STEM Crisis or the Skills Shortage. America simply isn’t producing enough STEM graduates, and so our tech firms are pushing to expand visa programs and hire more foreign workers to fill the gap. Meanwhile, other countries like China and India have gained a competitive edge in qualified labor. In electronics alone, Asia is responsible for 90% of the world’s research and development.

What are we doing about it? Since the 1980s, various public and private entities have worked to bridge the gap between STEM supply and demand in America. The shortage of STEM grads means we lack qualified researchers and practioners as well as qualified educators to stimulate growth in STEM fields. Thus our problem is two-fold.

One approach involves offering incentives like scholarships, loan-forgiveness, and higher pay aim to attract more teachers to STEM fields. According to Time Magazine, Math For America provides $100,000 fellowships for math teachers and Partners in Science gives science teachers the opportunity to undertake actual scientific work at national laboratories during the summer.

Another approach involves exposing students to STEM subjects early on and amping up primary and secondary education to better prepare students for these rigorous careers. Scholarships, hiring bonuses, and other attractive incentives target students as well. Many STEM programs are working to retain entering STEM majors (60% of whom will switch to non-STEM majors after taking intro courses), and they are pushing for greater enrollment of women and non-Asian minorities, who currently hold a disproportionately low share of STEM degrees.

The US Department of Labor projects that 2 million STEM-related jobs will be created by 2014. Post-recession job growth is great news, but that projection gives us less than 2 years to prepare 2 million workers for STEM careers. It seems the gauntlet has been thrown. Can we rise to the challenge?

To keep up with news on the economy, employment, education, and other industry updates, subscribe to our blog.

May 15, 2012 by Kendal White

Encouraging Insourcing to Revive the Economy

‘Made in America’—how important is it?

It’s no secret that American manufacturing has struggled since the late 1990s. We’ve seen massive layoffs and a growing trend to outsource jobs overseas—with some companies moving more than 90% of their manufacturing to countries in Asia or South America. But there is hope on the horizon. Over the past two years, the manufacturing industry has regained some of its former strength and added more than 400,000 jobs here at home.

The White House has turned its focus towards domestic manufacturing. In his State of the Union Address earlier this year, Obama advocated that insourcing would stimulate economic recovery. Companies like Ford, Honda, General Electric, Caterpillar and Intel have already moved plants back to the US, and the current administration encourages other American companies to follow suit.

“To create an economy that is built to last,” Obama announced, “we must ensure that the next generation of products are not only invented here, but manufactured here as well. Right now, companies get tax breaks for moving jobs and profits overseas. Companies that choose to invest in America, they get hit with one of the highest tax rates in the world. Does that make any sense? It’s time to stop rewarding businesses that ship jobs overseas.”

To encourage insourcing, the Obama administration proposed tax incentives for companies that return jobs to American workers. The White House also introduced the National Network for Manufacturing Innovation, intended to accelerate innovation by investing in manufacturing technologies. By bringing together industry, educators, and federal and state agencies, the network aims to

Bridge the gap between basic research and product development
Provide shared assets to help manufacturers access cutting-edge capabilities and equipment
Educate and train students and workers in advanced manufacturing skills

With a united effort to reshore, it looks like the tides will turn for American manufacturing. Based on a recent survey, economists predict that one third of American companies worth $1 billion or more will bring back manufacturing plants that moved overseas during the past two decades. The outsourcing trend may be losing steam as our technology improves and domestic manufacturing becomes a more viable option.

Check out UniTherm’s American-made insulation jackets that help manufactures save significantly on energy costs.

May 11, 2012 by Kendal White

Manufacturing Matters: 5/11 Weekly Wrap Up

The New York Times reports that manufacturing is “one of the few bright spot of the recovery, restoring 489,000 jobs since the beginning of 2010.” The article also describes geographic distinctions in growth, with half of the most manufacturing-specialized metropolitans now located in the Midwest.

Plastics News reports that in California a controversial pro-plastics lesson has been removed from a new statewide curriculum on the environment. After the EPA looked over the proposed curriculum, the section titled “Advantages of Plastic Shopping Bags” was replaced with recycling statistics in an 11^th grade textbook.

image from flickr

ICIS News announces that researchers at technology company Siemens have developed an alternative to ABS plastic. The new material—made with 70% renewable content—is the result of a three-year project funded by the German Research Ministry and was successfully used to make a vacuum cleaner cover.

image from icis.com

GreenBiz examines the Sustainability Leadership List, which recognizes environmentally-conscious companies each year. But because some criticize the results, they also discuss plans for the Global Initiative for Sustainability Ratings that would develop a standardized method of measuring and ranking sustainability performance.

Plastics Today recognizes Dignity Health, the founding sponsor of the Healthier Hospitals Initiative, as one of the first hospital groups in the country to start using pigment-free patient plastics. This California-based healthcare organization is a leader in sustainability efforts to reduce hospitals’ impact on the environment by adopting innovative alternatives.

May 8, 2012 by Kendal White

The Evolution of Insulation

As we grow more aware of our environmental impact—and as utility bills grow more costly—energy efficiency becomes a central concern in construction projects and building updates. LEED certifications set efficient buildings apart from the rest. Pink attic insulation doesn’t quite cut it anymore.

Natural Insulation
Although it’s a hot topic now, energy efficiency—insulation in particular—is nothing new. Since the beginning of time, the Earth and its inhabitants have found remarkable ways to regulate temperature. Atmospheric gases gather in the ozone layer, water surrounds land, mammals grow fur and store body fat, birds are born with feathers, and early on, humans discovered heat-trapping material like wool.

We have always put extra effort into shielding ourselves from the elements. Early humans built their homes out of natural insulators like grass, leaves, straw, mud, ice, and mountainsides. And landscaping wasn’t always about aesthetics—trees planted near houses provided precious shade and insulation.

While keeping extreme temperatures out, people also came up with ways to generate heat within. Some buildings in the Roman Empire and ancient Korea used empty spaces in floors and walls to conduct air heated by furnaces. By 1700, Russian engineers began developing water-based systems to circulate heat.

Synthetic Insulation
With the advent of modern heating systems came the need for better insulators. After all, gas and electric systems don’t come cheap like heat from a wood-burning furnace, and they create conditions that need to be regulated in order to work properly.

In 1930, Dale Kleist, a researcher at the Owens-Illinois Glass Company, made one of those lucky mistakes that so often leads to a monumental discovery. While trying to seal two plates of glass together, he accidentally shredded the glass into tiny fibers with a high-pressure air hose. Thus, fiberglass was born and soon found its most common form in blanket insulation.

Meanwhile, manufacturers began to realize the benefit of insulating not just their buildings but their heat sources as well. This helped protect workers and equipment, save energy, and improve overall efficiency.

Custom Insulation
We’ve come a long way since adobe huts and igloos. Today, engineers use R-values (the measure of thermal resistance) to quantify and compare the insulating capability of different materials. In this way, they can combine the most effective insulators and create premium insulation.

Visit unitherm.com to learn more about custom insulation systems.

May 4, 2012 by Kendal White

Manufacturing Matters: 5/4 Weekly Wrap Up

Another great week ripe with industry news. Here are the highlights:

Plastics News reports that the shortage of nylon 12 has led the auto industry to seek alternatives resins to use in fuel lines, connectors, tubes, and other key components. Molders and resin makers have offered a variety of possible alternatives, and automakers have established a system to begin testing.

The Huffington Post addresses the current the job market as US Congressional Candidate Stacey Lawson proposes a plan for creating jobs and rebuilding our middle class. Lawson stresses that we can by reclaim the American dream by “restoring the high-wage jobs that are the foundation of a sustainable economic recovery,” and she lays out 7 priorities to help us get there.

Clean Technica overviews the Department of Energy’s voluntary energy savings specifications designed to help building owners, operators, and manufacturers develop minimum performance requirements. The DOE recently released new specifications for lighting troffers and parking lot lighting, which could reduce energy use by 40%.

image from cleantechnica.com

Industry Intelligence announces a new compostable bioplastic film that extends the shelf life of fruits and vegetables by up to five days. The new film, developed by Sira-Flex Resolve, creates an ideal atmosphere to better preserve stored food.

image from flickr, courtesy of I-5 Design & Manufacture

And in a free webinar, Design World discusses how Design for Manufacturability (DDM) eliminates many restraints associated with conventional manufacturing. The webinar examines how DDM can create plastic parts, layer-by-layer without machining, molding, or casting.

If you like the Weekly Wrap Up, follow our blog to receive more updates and industry news every Friday.

May 1, 2012 by Kendal White

How to Join the Better Buildings, Better Plants Challenge

Going green. Saving energy. Encouraging efficiency. Reducing carbon footprints. Promoting eco-friendly practices. Being environmentally conscious. Conserving resources. It goes by many names, but the social movement is undeniable.

I remember seeing for the first time the trendy “Save the Planet” tees cropping up in clothing lines of popular retail stores. Years later, it turns out that going green more than a fashion trend. It is a compilation of personal and political choices that continues to build momentum worldwide.

We can see big impacts, too, when we look at the sum of our efforts. That’s why government and corporate entities promote going green, leading by example and initiating challenges to get others involved.

Better Buildings, Better Plants Challenge

Last year, President Obama and former President Clinton issued the Better Buildings Challenge and extended the challenge to industrial plants for an even greater impact. Because buildings consume about 20% of all the energy used in the US, the initiative’s long-term goals include

Updating American buildings to make them 20% more energy efficient
Saving American businesses nearly $40 million in energy costs

With the help of energy efficiency products, services, technologies, and partnerships, several industrial partners have stepped up to the challenge—3M has 78 participating plants, Alcoa has 30, Nissan has 3, and GE has 125 million sq. ft. of plant space (to name a few).

But you don’t have to be a big name with copious plant space to make a difference. Think of it this way—as a little guy, your carbon footprint is already smaller so you don’t have to make such extravagant changes. Every little bit counts.

To join the Better Buildings, Better Plants Challenge

Assess your building portfolio to determine energy efficiency opportunities and publicly pledge an organization-wide energy savings goal for the next 2-5 years.
Announce and initiate a showcase project on 1 facility (retrofit, retro commissioning) and develop an organization-wide plan to achieve your energy savings goal.
Share your experiences with energy efficiency solutions, your organization-wide energy savings, and the energy performance at individual facilities for recognition.

In return for your commitment, the Department of Energy agrees to support you via expert technical assistance, connect you to a network of allies, and provide you with national recognition. Win-win-win.

What are you doing to green your building? The Better Buildings Challenge is just one way you can contribute to the social movement. Incentives are abundant, and the payoffs reach far and wide. For starters, you can insulate your equipment to conserve energy and maximize efficiency, and when you start seeing the savings, you can move on to other areas like HVAC and lighting for a complete energy-efficient overhaul.

April 27, 2012 by Kendal White

Manufacturing Matters: 4/23 Weekly Wrap Up

It seems there is always so much exciting industry news, so we welcome you to our first of many weekly wrap ups.

The Economist says we have entered a third industrial revolution. With the advent of additive manufacturing and the refinement ofrobots, we can glimpse the future of factories. As manufacturing goes digital, we see new processes emerging that are vastly different from the 20^thcentury assembly lines.

image from economist.com

MIT discusses whether increasing complexity in engineered systems warrants a new approach to safety and testing. MIT professor Nancy Leveson claims that our modern, ever-evolving systems are more vulnerable to accidents, and she advocates a holistic, sum-of-its-parts approach over traditional safety engineering practices.

available at amazon.com

The Huffington Post poses the question, is Obama getting serious about manufacturing? Huff Post says that if the government acknowledges manufacturing as a stable and productive industry—a “uniquely important sector”—that support can benefit the broader economy and build a stronger country.

GE discusses the “robust renaissance” of manufacturing “fueled by new technologies, software, innovation, and lower energy costs” and posts a great infographic highlighting industry growth and the power of insourcing.

Envision Plastics announces the partnership between Alpha Packaging and Arla Foods, a partnership aiming to eliminate landfill waste with a zero-carbon facility. To launch the sustainability strategy, Alpha Packaging will produce milk bottles with 50% recycled material. Arla Foods recruited Alpha to mold and handle the bottles on site with two goals in mind: consuming the lowest amount of energy possible and creating the most environmentally advanced dairy in the world.

image from envisionplastics.com

Metal Architecture says that reducing factory footprints is not only environmentally friendly, but economically smart as well. Building owners who focus on decreasing carbon emissions and reaching LEED standards enjoy numerous benefits: improved image and marketability, greater employee engagement, higher renter rates, and more incentives.

We hope you enjoyed our first edition! Keep checking in for more industry updates from the top news sources.

April 24, 2012 by Kendal White

International Standards for Energy Management: How ISO 50001 Can Help Companies of All Kinds

“Individual organizations cannot control energy prices, government policies, or the global economy. But they can improve the way they manage energy.” –ISO Secretary-General Rob Steele

Energy is one of the largest controllable expenses of your plant, or of any building for that matter. And luckily, as more and more building owners realize remarkable ROI in energy-saving strategies, the amount of related information continues to grow.

In fact, a quick Google search for energy management returns about 54,800,000 results, which gives us about 78 pages to wade through. Of course, no one has time for that, so we usually just collect tidbits of advice we hear about going green and put them to use as best we can.

For example, at home I know to keep the thermostat under 68° in the winter and over 72° in the summer for better energy savings. I know to run the dishwasher only when it’s full to maximize water use. I know to open the shades during the day to let in natural light. I’m sure you’ve heard similar rules of thumb.

So we’ve got the basics down, but managing energy in an entire plant requires a bit more forethought than simply turning off the lights when we leave the house.

download avaiable at iso.org

Fortunately, the International Organization for Standardization (ISO) launched an energy management standard last summer. According to ISO, the energy standard—ISO 50001—will provide industrial plants, commercial, businesses, government facilities, and entire organizations with “access to a single, harmonized standard for implementation across the organization with a logical and consistent methodology for identifying and implementing improvements.”

Twenty-six US facilities, including 3M, Cook Composites, Dow Chemical, Nissan, and Volvo, participated in ISO 50001 pilot programs. In addition, the Department of Energy endorses ISO 50001 as a “proven approach for US industrial commercial facilities to plan, manage, measure, and continually improve energy performance.”

Companies implement these energy standards to reduce their energy consumption and environmental footprint, but they can become ISO 50001 certified as well. On March 8^th of this year, Volvo’s Dublin plant was the first US facility to achieve certification. This third-party verification can afford companies a competitive edge and greater confidence in their supply chain.

For those that utilize it, the energy standard will be hugely helpful as it takes the guesswork out of energy management. Instead of the trial and error strategy I use at home, haphazardly turning the thermostat up or down, ISO 50001 provides an explicit framework applicable in any company—public or private, large or small. Companies worldwide can now adopt best practices in energy management.

Have you begun working towards your ISO 50001 certification? What other energy management tools—software, audits, etc.—do you use at your facility? If you’re kicking off a new energy management program or you’re working to keep your energy output in check, get a customized energy report today.

March 20, 2012 by Kendal White

Less is More and Lean is Better: Managing Inventory in Manufacturing

The concept of lean manufacturing is simple. Much like a diet for your facility, the goal is to reduce your waste (like you would your waist) for healthier operations. It’s not about starving your business because, let’s face it, you can’t run a marathon or outlast competitors without proper sustenance. Lean strategies are about taking in only what you need and making the most of it—kind of like politely pushing away a plate of food when you’re full rather than stockpiling calories for a later date.

Now I know by March many of our weight loss resolutions have run their short-lived and often unfulfilled courses, but it’s always a good time of year to take on a new style of inventory management.

How manufacturers manage inventory
Many manufacturers produce products in large runs, even when the demand for that product is low. Products are stored or kept in inventory until they are eventually sold, which often leads the manufacturer to overspend on storage. When production runs are too large, manufacturers run the risk of filling inventory with products that might become outdated and remain unsold.

Why lean strategies are more efficient
A crucial component of lean manufacturing involves controlling inventory by reducing excess production. This means implementing a system for monitoring inventory and producing products in smaller runs rather than keeping excess inventory in storage.

Wait, it takes time and money to modify the way you manage inventory and thin out the production line. But just like dropping a few pounds, the payoff doesn’t occur overnight. Soon enough, the savings from storage costs and unnecessary waste will find their way to the bottom line. It’s well worth the change—just ask Toyota, Boeing, Caterpillar, and Xerox.

Not only will lean strategies lower your overhead costs, but they will also challenge your employees to think critically to improve existing procedures. No reason to keep things the way they are just because—hopefully your facility is always on the look out for more efficient ways to operate. Plus, you won’t have to feel that little pang of guilt as you throw away perfectly good products because of bad timing.

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