Beruflich Dokumente
Kultur Dokumente
by Don Costanzo
senior editor
Making adjustments
In what have been trying times in
the wire and cable industry, compa-
nies are being asked to do more for
their customers. And, the companies
that design, manufacture and distrib-
ute measuring and testing equipment
are no exception.
Paul McDermott, director of sales
and marketing at Clinton Instrument
DECEMBER 2001 65
provide more accurate and detailed
information at often lower prices
observed Donald Bugden, the compa-
nys vice president of marketing.
Cost savings for the customer come
from scrap reduction, elimination of
down time and efficient integration of
automatic inspection and data concern-
ing product quality into the production
process, Bugden said.
Antonio Spizzamiglio, president and
sales manager of Aeroel Srl observed
that growing competition from Asian
companies is forcing the European Clinton Instrument Companys High Frequency Sine Wave Spark Tester.
steel wire testing industry to enhance
efficiency, reduce costs and improve wheel that sits on the product as it is a real pressing need to maximize
quality in order to survive. Companies moves through a process. This method production speeds while minimizing
in Asian countries, he noted, can rely may still be cost effective, but only scrap generation. Zumbach has been
on a cheaper workforce and are not when product is sold by the pound or offering the tools to achieve this all
impaired by strict safety and environ- rewound to accurate lengths. along, except today customers seem to
mental regulations. Reliable measurement allows manu- be more inclined to really invest time
It is necessary to identify new prod- facturers to give away less product and, (and money, where still available) to
ucts and applications, innovative meth- in some cases, ship product on the lower get a tighter grip on productivity, pro-
ods and technologies and also to con- tolerance with confidence that the pack- duction costs and quality.
ceive and implement brave and creative age will not be too short, he said. Henzi also noted a greater need for
marketing strategies and techniques, Also, with accurate measurement and customer support.
Spizzamiglio said. Our customers are creativity, a packaging system can be Some customers downsized and lost
increasingly asking for on-line diameter programmed to help make decisions to highly qualified people while the
control instruments that can operate on reduce scrap when defects are found. requirements (production speeds, pro-
any machinery in a reliable and efficient For example, Zampogna noted that duction specifications, etc.) increased,
way, for a small price or anyway for a length tolerance specifications and alter- he noted. More has to be achieved
price adapted to the actual economical nate package lengths can be programmed with fewer people, and some cus-
advantages they offer. into the line PLC, and when defects are tomers are more inclined to make use
Consistent, accurate length measure- found, the optimum use of good product of our service specialists to help them
ment can reduce costs, explained is quickly decided and produced. to optimize their measurement and
James Zampogna, vice president of Sikora International USA President control systems.
sales and marketing for MGS/Hall, Jeff Swinchatt observed that recent Jeff Kohler, vice president of TLA,
who agreed that reducing costs has market forces have impacted his com- Inc., noted that there is constant pres-
quickly become a top priority. panys customers in a variety of ways. sure to improve and document quality
While most wire and cable applica- Cost reduction programs are balanced while lowering costs.
tions use four basic types of length with development initiatives to deliver Information management has become
counters (single wheel, dual wheel, new or enhanced products at attractive a key part of the manufacturing
caterpillar and laser), Zampogna noted price levels, Swinchatt said. process, Kohler said. Companies are
that some manufacturers still use a The shrinking market, combined pushing to download machine setup
simple manual counter, which mea- with overcapacity in some segments information to the plant floor, computer-
sures by using a single rubber coated of the wire and cable industry, have ize data collection and archiving for on
led to fiercer competition, consolida- demand reporting. A paperless office
tion and streamlining of operation, integrated with a paperless plant floor
noted Ernest Henzi, Zumbach Elec- means efficiency, streamlined operations
tronics Corporations senior vice and ultimately cost savings.
president of marketing. Customers appreciate the fact that
The need for uniform quality, cost measuring and testing companies con-
reduction through shorter start-up tinue to look for ways to cut costs, while
times, raw material savings and scrap at the same time improve their product
reduction is even more pronounced at offerings, said Brian Osmondson, TSI,
this time, translating into a more acute Inc., marketing manager.
MGS/Halls caterpillar-type measuring need for accurate and dependable on- I believe that customers are smart and
machines are designed to provide accu- line measuring and control instrumen- recognize they need to produce high-
rate length measurement with no slippage. tation, Henzi said. We feel that there quality products and improve productivi-
DECEMBER 2001 67
The cost of adding additional fea- of cable at various speeds. Bugden believes that technical improve-
tures will be minimal and the time In the packaging cycle there are ments will concentrate on developing
spent here will enhance our brand, much violent accelerations and decel- and combining techniques in the future
Cleveland Motion Controls Dan Burns erations, and in order to avoid sliding to allow detection of unacceptable prod-
said. Unfortunately in the next year or of the cable on the pulleys we have uct variances that cannot be accom-
two, our growth will be outside of our reduced the plished with the present
core market in the wire and cable inertia of the state of the art.
industry. We will be introducing our pulleys at The overall requirement
technology to other market segments the mini- is to find and, if possible,
and product types not so heavily mum possi- measure and identify these
affected by the economic slowdown. ble, said variances by type, he said.
When it comes to product innova- Zanni, who This must be done while
tion, DCMs Perry Chattler believes added that reducing the incidence of
the customer must be King. the company mistakenly identifying
We firmly believe that the best input was able to acceptable product as non-
for our new product developments do this by conforming.
comes from the companies that will creating a The greatest growth, he
buy them, he said. In response to fusion of added, will come from the
input from our customers we are very light ability to tailor systems for
focusing on cost reduction, additional alloy alu- each customer that can
features and performance enhance- minum, on obtain and assimilate mea-
ments. Cost reduction is being which an surements of a products
achieved by scaling down the size and application quality throughout the pro-
complexity of our offerings. of Vulkollan duction process, so as to
Chattler refers to these new offerings has been EFAFs Renzo Zanni said length mea- improve process control as
as bench top units, which are differ- applied to suring systems are made more effi- well as quality control. As
ent than older systems that require increase the cient and reliable by avoiding the an example, further devel-
their own chassis, and so forth. adherence sliding of the cable on the pulleys. opment of electromagnetic
Additional features are being added and the wear acoustic transducer
constantly to the main bench top unit, endurance. (EMAT) techniques may
Chattler noted. For example, the ES- The upper pulleys are assembled on facilitate adding the unique capabilities
2G can test most needed high frequen- a support linked to a pneumatic cylin- of ultrasonic inspection to the mix with-
cy parameters. Separate options can be der with pressure variables which out the inconvenience of having to pro-
added for low frequency parameters or allow the regulation of the force of the vide a coupling agent between the
items such as LCL and transducer and test speci-
transfer impedance test- men.
ing. New options are TLA, Jeff Kohler noted, has
always under considera- two areas of technical focus:
tion and development. As gauging and data processing.
for performance enhance- In the area of gauging, our
ments, the ES-2G capabil- clients continue to expect
ity speaks for itself. With higher accuracy to meet ever-
an upper frequency test tightening product specifica-
limit of 1.8GHz it far sur- tions on wire, cable, optical
passes any competitive fiber and faster measurement
system on the market rates to support production
today. In addition, new efficiency (i.e. higher line
calibration routines have speeds), he said.
been introduced to the In the area of data process-
system to also make it the ing, clients are demanding
most accurate. Flexibility is engineered into the components to provide Magnetic
operator ease of use, access to
Renzo Zanni, general Analysis Corporations equipment in a form that can be combined in data and configuration over
manager of Engineering a unique system according to a customers needs. networks, and integration
Future Automazione with other applications hori-
Flessibile Srl (EFAF), said zontally, such as SPC and
his company has focused HMI/MMI software; vertical-
on making modifications to its length pulleys on the cable avoiding sliding, ly with applications such as ERP soft-
measuring system in order to make it he observed. ware.
more reliable and efficient for all types Magnetic Analysis Corp.s Donald (continued)
DECEMBER 2001 71
working and beyond. Depending on how it is used, TLAs mercially available for at least three
Like in the case of the laser printer Jeff Kohler said equipment certainly decades.
example, Henzi said. The end user is might be considered a commodity. Each laser scan is quite sensitive to the
often not in a good position to make For many applications, there are a flatness and irregularities of the mirror
an informed decision, relying on brand handful of choices of laser scan surface, he explained. No matter how
names rather than technical facts. micrometers that would suffice, he much grinding or polishing of the mirror
Sikoras Jeff Swinchatt noted that he said. In those cases, one could say is performed, each side of the polygon
is often asked the mirror is different from
question of whether the other. As a result,
or not laser technolo- multiple laser scans must
gy has become a be averaged together to
commodity. compensate for the mirror
The wire and surface irregularities in
cable industry has order to obtain a single
accepted the perspec- diameter reading.
tive that this technol- In addition, tradi-
ogy is useful and tional laser scanning
people find it valu- diameter gauges are
able especially the very sensitive to motor
operators you talk TSIs Brian Osmondson works on one of the companys Holix gauges, which wobble due to bearing
with, he said. From employs Holoptics technology to create fast and accurate diameter gauges with wear, Osmondson said
the viewpoint that a flaw detection capabilities. of the commodity item.
commodity is some- As bearings wear out,
thing that is no longer a specialty item, that the gauging is a commodity. the motor begins to wobble and the
one can argue both sides of this What tends to differentiate in these mirror tilts off axis. A reflected laser
answer. cases is data processing capabilities, scan generated from a tilted mirror
More cable makers accept that diame- operator interface and non-technical causes the laser scan to tilt by twice as
ter gauges are part of their process issues such as support and cost, he much as mirror tilt. The result pro-
today, Swinchatt said, and added a cable added. Our systems run on the PC plat- duces erroneous measurements and
maker would rarely run a production form, utilizing our TLAser400 Microm- requires the gauge be repaired.
line without measurements and controls. eter Interface card. Each card supports TSI Holix gauges employ patented
Ten years ago, this was not the case. up to four micrometers, and up to four Holoptics technology to create fast and
Our customers today understand the cards may be run in one PC. Support for accurate diameter gauges, which also
cost savings and quality control impact up to 16 micrometers on a single plat- have flaw detection capability, he said.
this technology contributes. form offers substantial cost savings, Osmondson explained that instead of
And just as there are different cables without sacrificing performance. using a polygon mirror to generate
being made, there are different man- The testing of electrical parameters each laser scan, the Holix gauge uses a
ners in which the diameter gauges can of copper communication cable is spinning holographic disk. The holo-
be applied, Swinchatt noted. hardly a commodity product, explained grams on this disk, and other holo-
Each process must be examined for DCMs Perry Chattler. DCM differen- graphic optical elements, are based on
the correct manner which to examine tiates its products in many ways, but mathematics, not grinding and polish-
the cable product and control the appli- the three most significant are system ing a mirror, he noted. They consist of
cation, he said. When this type of performance, flexibility and after sales a series of closely spaced thin slits or
expertise is required to apply this tech- support, he said. grooves and are produced much like a
nology, it would appear to me that we The companys ES-2Gs range of fre- musical or data CD, where each disk is
remain in a specialty market. quencies and accuracy clearly differen- a perfect copy of the master. When a
Aeroels Antonio Spizzamiglio tiate it from anything else on the mar- laser beam is passed through a holo-
believes the laser gauge is gradually ket, said Chattler. Flexibility is gram the beam is diffracted (not
becoming a commodity or at least an addressed by modular product design. reflected) and exits at a different angle.
element that is starting to be considered Rather than just producing one system This, Osmondson said, is what makes
as a standard component of the draw- and expecting customers to integrate the product a specialty product.
ing bench, provided that cost and per- our system into their test scheme, we
formance conditions are met, he said. provide them with a menu of options to Making changes
This is even more evident, he said, choose from.
when the application of laser gauges to TSIs Brian Osmondson noted that Aside from the demands of the cus-
online monitoring is considered, which traditional laser-based diameter gauges, tomer, there are plenty of other factors,
helps to avoid the cost of manual checks, which operated by reflecting a laser from changing standards to govern-
cuts scrap enormously and in the long run beam off of a spinning polygon mirror ment intervention, that may influence
widens plant automation, he explained. to create a laser scan, have been com- and affect the way companies do busi-
AUGUST 1999 73
chip technology that has enabled TSI and inefficient networks of agents, dis- economies of scale, the availability of
to embed the signal processing on a tributors and brokers, Spizzamiglio tools and application software, PC-
single chip, inside the gauge (optics said. This is our way to meet the based instrumentation, networking and
sensor), he said. The result is the growing need for cost reduction. It is a variety of other accessories means
TSIs LaserSpeed gauge. not a simplification or an impoverish- continued cost savings, faster develop-
In my opinion, the Internet is the ment of the product, but a drastic cut ment cycles, far more choice, flexibili-
main innovation that has been having to renounce able costs, such as mar- ty and future adaptability.
and will continue to have a consider- keting. Meanwhile, Dan Burns noted that
able impact on our work, Aeroels Perhaps more than the innovation of the challenge for Cleveland Motion
Antonio Spizzamiglio said, touting the product and process, this is the play- Control is the need to have the com-
Internet as a fast, low-cost, universal ground where the future of our busi- panys products certified for Europe
and interactive form of communica- ness will be set, he added. and Canada, as we expand into mar-
tion. TLAs Jeff Kohler echoed Spizza- kets outside the USA in order to
It [the Internet] allows us to estab- miglios sentiment. We think that the maintain volume and have a chance
lish a direct contact with our customers PC is critical to long-term operational at growth.
and partners, and so to by-pass costly success for companies, he said. The
DECEMBER 2001 77