Packaged 3D

A chocolate assortment in a vacuformed tray by Evan-Amos

A chocolate assortment in a vacuformed tray by Evan-Amos


Life could be a box of chocolates. The challenge in this era of mass customization is that the assortment of flavors that we want to buy changes with the wind. If you look at the picture carefully you will discover that the pockets match the shape of the chocolates. This means that if you want to change the assortment you require a new mold. The associates filling the box also find it hard to adapt to continuously and randomly changing customer order. It would also be helpful if the vacuum molded tray had some visual management labels to guide in the fulfillment activity.
Enter 3D printing. Invisalign pioneered the use of 3D printed molds to shape plastic sheet.
Vacuformed orthodontics are shaped over 3D printed molds by Smikey lo

Vacuformed orthodontics are shaped over 3D printed molds by Smikey lo

Since every retainer created is different, the 3D printing process also molds into each item identification information. Why did Invisalign choose plastic sheet?
From the earliest blacksmiths shaping swords, the engineering community has discovered that it is possible to increase material strength if the application does not need the high strength in all directions. The bio-compatible plastic used by Invisalign actually works as a retainer, whereas the 3D printed plastic used to make the mold is too brittle and you would not catch me sticking it in my mouth because it still contains active plastic precursors. Other plastic composite sheet can be even stronger because reinforcing fibers can be laminated into the mix
Fibers add strength to plastics and rubber by PerOX

Fibers add strength to plastics and rubber by PerOX

For example pneumatic car tires must have embedded fiber reinforcement to withstand the applied forces. Airplane manufacture is a logistic nightmare. About 100,000 parts must be manufactured and gathered together in the right order to make a plane come together. The Boeing engineers joke that FISH (first in still here) has replaced FIFO (first in first out) as their accounting system. Boeing in their Moonshine Project determined that staged delivery to the assembly floor is more that sending the parts. The parts themselves are useless without the matching tools to install them. In their historic system workers spent much of their working day traveling back and forth to the tool cabinets around the working area. As we gain engineering control, the implementation of molded tool trays on 3d printed molds is an effective shadow board so that it becomes possible visually to determine in the warehouse that all of the required tools are sent with each cart of parts.
747 airplane parts and tools are delivered together by Jeff McNeill from Chiang Mai, Thailand

747 airplane parts and tools are delivered together by Jeff McNeill from Chiang Mai, Thailand


Some of the solution for the shortage in transportation capacity has to come from efficiency. It would be easier if the marketplace didn’t want mass customization at the same time. I can picture us evolving to 3D print to order shipping trays so that full density skid size loads can be assembled upstream enabling fast loading and less unprofitable empty space in transit.

Modern Moats

Herstmonceux Castle and Moat for TO6410 cc Dave Croker

Herstmonceux Castle and Moat for TO6410 cc Dave Croker


Planners who were trying to safeguard valuables back in the middle ages discovered that it takes more than fortifications to succeed. This is especially true when the fortifications have secret doors that were installed by the builder. I suspect that the fortress defenders discovered that the addition of a moat also flooded the tunnels under the walls. In this digital age, the task of defending a company’s digital fortress is daunting. The magnitude of this task will only increase as more of our foreign-built devices become internet connected.
by Stan Schneider Real Time Devices

by Stan Schneider Real Time Devices


As revelations by Edward Snowden and others have demonstrated, the fortress walls of these IoT (Internet of Things) devices come with pre-installed secret doors. This fact has not escaped the thieves that exploit these weaknesses. In much the same way that Google crawls the web looking for home pages, a search engine named Shodan crawls the web looking for the hidden back doors http://www.forbes.com/sites/kashmirhill/2013/09/04/shodan-terrifying-search-engine/. Using this search engine to help them, I am not surprised that the thieves find that some of these doors are unlocked. So how do you go about installing a moat before the thieves make off with the crown jewels? What does a modern moat look like? The first moat of the electrical age was related to the high voltage wires needed to transmit power for long distance. Nickolai Tesla working for George Westinghouse developed the high voltage power system we use today. Glass insulators kept the high voltage from shorting to ground.
Sophisticated insulators stop the loss of high voltage power

Sophisticated insulators stop the loss of high voltage power

It is very exciting when the salt we use on the road causes massive fires in the substations melting the conductors. Obviously the fuses blow, but most of us have also lost a TV, radio or computer because the high voltage finds its way into our electronics. The fragile electronics in our computer chips died regularly, until we discovered how to use light in the form of opto isolators to build a non-conducting moat around the processor.
light waves protect microprocessors from voltage spikes  by Inductiveload

light waves protect microprocessors from voltage spikes by Inductiveload


Light can also be used to protect the program running the computer from hacking and malware. Early in the development of microelectronics a type of memory called UVprom was invented. Bright ultraviolet light bathed on the chip erases the memory.
Ultraviolet light erases this chip CC by SA 2.5  ST Microelectronics M27C2568-12FI

Ultraviolet light erases this chip CC by SA 2.5 ST Microelectronics M27C2568-12FI

The convenience of the electrically erasable chip has led to its wider use. In general, it is not convenient if spyware and malware are remotely added using the electrically erasable chip to steal the crown jewels. I suspect that the vandals of the middle ages would have liked conducting their raids without ever having to leave home. I believe that we will go back to locking in the operating program. It is promising to hear that Google is unveiling their Vault micro SIM card for a mobile phones. We will all be watching to see whether it actually improves security or is just to keep out every one but Google (and the NSA by hidden deal) http://www.cnet.com/news/googles-project-vault-is-a-security-chip-disguised-as-an-micro-sd-card/ This is probably why so many users cling to Windows XP (also named Windows NT) Daily web updates to fix the bugs in incomplete operating systems are a big gap in the moat we are trying to build around our data fortress.
In the early days of computing, many of us used time sharing. The derivative virtual machine adds one more level of security but it does not protect against back doors that were embedded in the parent operating system.
Virtual Marble Machine  CC by Torley

Virtual Marble Machine CC by Torley

I like playing video games, but if I am interested in data security I will go back to build and maintaining the moat. Windows NT is very stable and bug free operating system if is isolated from the web. Thinking in military terms it is better to have a mine field between you and the theives. We have all played minesweeper.
Memory with embedded "mines" can be built into the cables that connect to the internet

Memory with embedded “mines” can be built into the cables that connect to the internet

Remote probing is a lot more difficult if only a small amount of data is availaible at one time in a two directional buffer memory and random memory addressed are mined.
Currently 40% of the cost of new vehicles is software. Companies who wish to remain in business must take building a moat against the “Great Cannon of China” more seriously

Robot Vision

Vision - The holy grail of robotics

Vision – The holy grail of robotics


We would like to have robots perform the tasks that we as humans do not want to do. Many of these fall into the heavy, dangerous, repetitive, precise, finicky categories. As humans we learned to accomplish these types of actions as little children, so we do not have a step by step roadmap on how to get this type of task done
The blind leading the blind By UR INC Motoman SDA10 at Smith Springs Lab

The blind leading the blind
By UR INC Motoman SDA10 at Smith Springs Lab


Most of us who have implemented robots find that blind repetition of actions, however well conceived leads to less than desired results. Real processes are not perfectly consistent and real parts have tolerances. As engineers we normally try to compensate for the fliers that we have experienced, but new types of defects emerge in the global race to the bottom. For example it was only recently that I had to fight with bolts where the hex head was partially formed. This totally jams the automatic feeding and installation equipment. Dumb and happy. The robotic automation cannot cull out the defective parts which is a simple task for the humans that they replaced. Fortunately in this case, I included a proximity switch in my arm end that could be used for sorting.
Capacitive proximity switches detect objects before they are hit

Capacitive proximity switches detect objects before they are hit


It is possible to use a proximity switch to measure to an accuracy down to .001 inch. (high accuracy measurements have a significant time penalty due to multiple probe motions) I recommend including extra vision catagory features when implementing new robot installations. In this fast changing business environment it is highly likely that your robots will need to be taught new tricks before they are taken out of service. Small investments in sensors like $100 proximity switches can be very useful in shortening the reaction time to unforeseen process challenges. The Fraunhoffer institute is pioneering in the implementation of capacitive “vision” In the linked article by Dr. techn. Norbert Elkmann the usefulness of advanced sensing is explored. “Manufacturing has great need of robots with high load carrying capacity for human-robot collaboration. Since the potential risk for humans in the event of a collision is naturally greater than when robots are smaller, the use of robots with high load carrying capacity in the direct vicinity of humans requires smart sensor systems such as capacitive sensors that detect proximity.” http://www.iff.fraunhofer.de/en/business-units/robotic-systems/capacitive-sensors.html
As we continue to use robots to replace humans, It will be necessary to create robots that incorporate human sensory capability. Touch will be one of the first areas that changes. Since material handling is one of the primary robot uses, controlling the applied force is a requirement. We have all been frustrated with the robot gripper in the arcade game. It drops the prize at every opportunity. If we wish to use a robot to replace humans the gripper needs tactile sensors. This mimics human touch using a strategy similar the human it replaces. Nerve endings, concentrated in our finger tips, transmit a whole bunch of data down the arm
Grippers have evolved from the arcade version to the state of the art Tactilus Multi-vector Sensor - Sensor Products Inc

Grippers have evolved from the arcade version to the state of the art Tactilus Multi-vector Sensor – Sensor Products Inc

Just force sensors by themselves may not be enough. It may also be necessary to have individual finger motion control. Other tasks arer even more sophisticated. Simply having force sensors may not be enough to prevent impact damage. The Lexus like most modern passenger cars has a ring of impact sensors around the body. Even though rush hour feels like bumper cars some days, it is not very effective to wait until the sensor detects contact as a strategy for safe following in traffic.
by METRO66 Wheeler Dealer Bumper Cars by Mariordo Driving Google Self-driving Car

by METRO66 Wheeler Dealer Bumper Cars
by Mariordo Driving Google Self-driving Car

As we look into the future of robotics, we will see a massive increase in the amount of data that is processed to accomplish the robot tasks. The current individual wires down the arm will be replaced by arm end processors and fiber optic links. Full vision control will occur in high volume premier applications, but cost limitations will result in selected use for other industrial tasks.

Mass Customization

One Size Fits All

One Size Fits All

This may sound corny but we live in the land of plenty. As Michael Pollen, the author of “Cooked”, puts it “If you are what you eat, and especially if you eat industrial food, as 99 percent of Americans do, what you are is ‘corn.'” http://www.ecoliteracy.org/essays/we-are-what-we-eat

Eat your cornflakes

Eat your cornflakes

But I don’t want to be corn. This is where the trend of mass customization it setting in. The industrial revolution was all about creating factories that could deliver massive quantities of identical product so that everyone could have some. The logistics system delivered full skid loads of boxes of cornflakes which populated the grocery shelves. The advent of computerized ERP has changed all of that. We now want to head to the store and grab the flavor of Gatorage that suits our fancy.
by Sarah Afshar - My love for Gatorade goes beyond

by Sarah Afshar – My love for Gatorade goes beyond

We just expect that the shelf will be restocked with the correct flavor without giving a second thought how the modern computerized ERP systems orchestrate that action on a JIT (Just In Time) basis triggered by scanning at the cash register. The plant that bottles Gatorade does not want to have any food remaining at the end of production each day to control bugs and pests. I am happy about that because it is a whole lot better method than using pesticides that could end up in the food we eat. Since the buying public is unpredictable the ERP system has to assemble a list for the the food warehouse of the needed flavors and quantities. The warehouse assembles (kitting) skids of the correct flavors of 80 lb gastorade concentrate packages in production sequence (in e-commerce this is called fulfillment)
Operators need a lifting device to assemble skids of heavy product

Operators need a lifting device to assemble skids of heavy product

A delivery run is made each day so that the correct raw materials are available at the start of each production day at the bottling plant. This is just one stop on the milk run that delivers ERP kitted bulk food products from the warehouse in the working day. We all got tired of eating cornflakes every day. Computer directed mass customization systems delivery the variety of goods that we want to the store shelves

Connectivity

Humans are all interconnected

Humans are all interconnected


The first long distance communication link was actually digital. The telegraph replaced flags, smoke signals and mirrors as the first reliable long distance link.
A telegraph key and sounder

A telegraph key and sounder

My dad’s best friend was a HAM radio enthusiast who worked for NASA. As a young child, I remember watching a teletypewriter translate radioed Morse Code and print at 20 words per minute. I thought the transmission was coming from Mars. Funny on today’s scale, in that this transmission was at the blinding baud rate of 8 bits/second. (still faster than you could send and receive Morse Code using the key.) The general public never wanted to learn Morse code so they migrated to the telephone, radio and television. My parents cottage / retirement home is on Lake Erie in a small village called Saybrook.
A lineman on a telephone pole.

A lineman on a telephone pole.


No it was no longer necessary to climb the pole to answer the phone. But, I can remember when a live operator came on the line to ask you what number you were calling from for billing. For us non-residents, it is mandatory to keep the cell phone plugged into the car charger so that you have enough broadcast power to last though a normal phone call. I am not surprised that Saybrook was a Finnish community. The equally sparse Finnish landscape prompted a Finnish company Telenokia in 1991 to invent the digital GSM G2 cell phone protocol. A digital link, initially at 40,000 bits/sec (the old telephone modems are at 48,000 bits/sec) replaced the G1 analog cell phone networks. This digital strategy made simultaneous voice and data transmission possible. We quickly adopted this communication link. Connected car services such as my IoT (Internet of Things) http://mileagetrakker.com automated milege report generation system became possible. Mileage Trakker even works in places like Saybrook which isn’t scheduled to upgrade beyond G2 cell coverage until next year.
Capture your full mileage deduction

Capture your full mileage deduction


Humans are funny creatures. In the near future we will all be transported by self-driving vehicles. I suspect that the resulting traffic jams will cause us to want enough cell bandwidth to synchronize the flow.
Computer control will stuff the roads

Computer control will stuff the roads

This is very similar to the task of keeping track of Kiva robots scurrying around a warehouse. Very high capacity “blanket” WIFI systems at 450,000,000 bits/sec by Extricom http://www.extricom.com are the minimum needed for this task. The actual bandwidth we will want is probably higher, in that it takes 32,000,000 bits per second, to transmit TV images to entertain us during the trip. We are watching all of our communication links converge into a single interconnected system.

KISS

KISS also applies to automation

KISS also applies to automation


KISS — Keep It Simple Stupid
Early in my career I was assigned the task of commissioning an $70,000 electric paint robot. Unfortunately at that stage of robot evolution, the seal design at the robot joints prevented it from painting more than the first part. The vapors shorted it out. What I learned is that it is more effective to tackle automating the simplest tasks first. Simple tasks take less investment to automate. Even though modern 6 axis robots can now handle painting tasks, combining them with required sophisticated guard enclosures places them far from the KISS category in my mind.
I was watching a 2 axis gantry “robot” carry engine cylinder heads at a Honda assembly plant in Alabama. Reminded me of a dog playing fetch with a stick. The jaws of the gripper opened and the human at the end was presented with the retrieved cylinder head. I install gantry robot transport systems for the same benefit, their simple motion and guards allow humans to safely work along side them. These robots do not care that I am comparing them to a dog. As Ada Lovelace wrote as her work began the digital age “The Analytical Engine has no pretensions whatever to originate anything. It can do whatever we know how to order it to perform”
A Spaniel fetches a stick by Kleuske

A Spaniel fetches a stick by Kleuske

Kiva robots are even simpler. They race to the other end of the warehouse and wait like puppy dogs for us to collect the item they have retrieved. All of this without the clutter of the rails and guards of gantry retrieval systems.
Moore’s law marches on. The cost of computers has dropped to the point where we can afford to automate even simple tasks. It is easy to write down date, starting odometer, location, finishing odometer and purpose for one business trip. You get pissed off enough to invent a better way when you spend a chunk of every Christmas vacation inputting a list of a thousand or so business trips so that you qualify to keep the $8000 to $9000 dollar business mileage deduction. I want to use the KISS principle to fix all the aggravations in my life.
Capture your full mileage deduction

Capture your full mileage deduction

It is nice that an affordable computer http://mileagetrakker.com can talk to the car and generate the log for me

Artificial Intelligence

Artificial Intelligence

Artificial Intelligence

Back in my early engineering days I was using the largest Cray Research computers in the world to analyse the stress and mode shapes of cars and trucks. This only worked if we could simplify the finite element test to the point where the computer could complete the calculation starting at 7:00 pm and stopping at 5:00 am when its task changed to supporting CAD. When I discovered that one of my friends had a personally owned computer of this magnitude at his desk I was intrigued. He had discovered that neural networking programs that simulate the way your mind tackles problems could be used to make a 6 figure income on the stock market. I linked him into some university researchers who discovered that complex numbers were more effective within neural networking programs. He traded this improvement into a 7 figure income. This is where computerized artificial intelligence shines. Keeping track of enough of the whole economy to succeed at managing a stock portfolio is beyond our mental capacity.
The engineering community continued to advance its versions of artificial intelligence. We call it adaptive control. Early examples include electronic spark advance. By 1982, it was finally possible to purchase power transistors that were capable of handling the spark control task. Later advancements included electronic fuel injection, which continuously adapts to dirt buildup, wear. and driver behavior. In military applications, stealth bombers and Ospery aircraft are beyond the ability of pilots to fly without adaptive computer assist. Along the way, I invented an industrial process which an operator could not supervise without the help of my patented adaptive control.

Slurry on Demand

Slurry on Demand


There is a perfect storm approaching. It will affect the people working for the big accounting firms the most. During World War II the Allied intelligence community invented what became to be called content analysis. They guided the war effort by combining the information gathered from every publication, like company newsletters and local news sources, that they could get their hands on. Any one item was not useful by itself. The company owners (stockholders) created the concept of accounting firms to look after their financial interests. The crooks who orchestrated the major scandals such as the World Com collapse took advantage of their incestuous relationship with the accounting firms doing the stockholder oversight, to mask their actions. Firms that are actually hired by crooks are reluctant to blow the whistle. The advent of big data combined with the evolved capabilities of the neural networking side of artificial intelligence are staged to crash onto the scene. Computers using artificial intelligence and content analysis will detect an impending company failure. The resulting analysis will enable a few stock investors to sell and get out. The stockholding public will have their confidence shaken. The lack of confidence in traditional accounting oversight will cause an accounting lean revolution where new more efficient controls emerge. We are all in favor of lean improvements until our own salary is the target. Lean improvements in manufacturing have left accounting expenses as a big target for computer technology inspired cost reductions. Usually this occurs as a season change in method.