“Manufacturing enterprises need more than just network connectivity – they need a complete solution that seamlessly enables Industry 4.0 applications while maintaining total control of their data and operations,” said Johan Bjorklund, CEO of Betacom. “By partnering with Siemens at MxD, we’re providing manufacturers with a blueprint for digital transformation, combining our private 5G expertise with Siemens industrial automation leadership to create a truly comprehensive platform for smart manufacturing innovation.”

The platform demonstrates how enterprises can:

• Deploy complete private wireless infrastructure behind their firewall
• Maintain full control of network operations and connected devices
• Enable seamless integration of Industry 4.0 applications
• Ensure end-to-end security across OT and IT environments

Developed specifically for Siemens U.S. manufacturing initiatives, the solution features:

• CBRS spectrum deployment in the coveted 3.55GHz – 3.7GHz range
• Advanced security framework developed with the MxD Cybersecurity Institute
• Proprietary cybersecurity built on 3GPP standards
• NIST framework compliance and Zero Trust Principles
• Betacom AirGap Protection for complete network segmentation

“This deployment represents a significant milestone in manufacturing innovation,” said Joel Green, Wireless Business Development at Siemens Industries. “The platform gives our customers the security and control they need while enabling the full spectrum of Industry 4.0 applications that drive operational excellence.”

Industries benefiting from this complete private 5G solution include manufacturing, logistics, defense contractors and supply chain operations. The MxD facility showcases practical applications including:

• Autonomous guided vehicles and unmanned forklifts
• Robotic systems and cobots
• Machine vision and quality control
• Real-time asset tracking
• Digital Twin Implementation
• Industrial IoT Sensor Integration

About Betacom

Betacom offers the first fully managed private 5G network service in the U.S., building on decades of expertise as a trusted wireless infrastructure provider for major carriers such as AT&T, T-Mobile, and Verizon. Founded in 1991 and headquartered in Bellevue, Washington, Betacom has established a reputation for delivering high-performance connectivity solutions to meet complex enterprise needs. With its secure, high-speed and scalable 5G services, Betacom continues to lead innovation in private wireless networks.

About Siemens Industries

Siemens Corporation is a U.S. subsidiary of Siemens AG, a global technology powerhouse that has stood for engineering excellence, innovation, quality, reliability and internationality for more than 170 years. Active around the world, the company focuses on intelligent infrastructure for buildings and distributed energy systems and on automation and digitalization in the process and manufacturing industries. Siemens brings together the digital and physical worlds to benefit customers and society. Through Mobility, a leading supplier of intelligent mobility solutions for rail and road transport, Siemens is helping to shape the world market for passenger and freight services. Via its majority stake in the publicly listed company Siemens Healthineers, Siemens is also a world-leading supplier of medical technology and digital health services. In addition, Siemens holds a minority stake in Siemens Energy, a global leader in the transmission and generation of electrical power that has been listed on the stock exchange since September 28, 2020. In fiscal 2020, Siemens Group USA generated revenue of $17 billion and employs approximately 40,000 people serving customers in all 50 states and Puerto Rico.

About MxD

MxD (Manufacturing x Digital) is where innovative manufacturers go to forge their futures. In partnership with the Department of Defense, MxD equips U.S. factories with the digital tools, cybersecurity and workforce expertise needed to begin building every part better than the last. As a result, our more than 300 partners increase their productivity, win more business and strengthen U.S. manufacturing.

Economical and user-friendly 

The LN4-11 provides shops several avenues to cut costs and improve profitability. Its adaptability to a variety of applications enables shops to reduce tooling inventories and costs. Operators simply change out the cutter’s inserts to go from one application the next. The tool’s front and helical insert pockets also eliminate the risk of incorrect insert placement to improve efficiency and reduce waste.

“The new Seco LN4-11 Helical Milling Cutter is the answer to the challenges shops face today,” said Seco Product Manager Magnus Engdahl. “It’s impossible to load the inserts of the cutter incorrectly, and every cutter body and insert feature an individual Seco Data Matrix code that provides access to cutting data and spare part tracking. It’s an excellent opportunity for shops to improve productivity and efficiency while overcoming the challenges created by lesser skilled operators.”

Four cutting edges for cost-effective milling 

The milling cutter has two different inserts. There are two cutting edges on the front inserts and four edges on the helix inserts. The design allows robust machining operations and aggressive material removal rates. Cost performance is enhanced, and tool life is improved. Inserts are available in a broad range of grades and geometries for a variety of operations and materials. The LN4-11 meets the demands of general engineering and automotive applications as well as those in the aerospace sector.

Each cutter’s individual Data Matrix code ensures easy access to all relevant tooling information including individual data metrics, cutting data, compatible products and spare parts.

About Seco

With its origins in Fagersta, Sweden and present in more than 75 countries, Seco is a leading global provider of metal cutting solutions for indexable milling, solid milling, turning, holemaking, threading and tooling systems. For nearly 100 years, Seco has driven excellence throughout the entire manufacturing journey, ensuring high-precision machining and high-quality output.

With v44, manufacturers gain unprecedented control over their production environments, leveraging new capabilities that integrate machines, streamline workflows, and enhance data-driven insights. This update marks a major leap forward for businesses looking to optimize their operations with cutting-edge software technology.

CAD/CAM 2D: Lantek Expert 

Lantek Expert v44 brings a host of enhancements designed to optimize CAD/CAM 2D workflows. At the forefront is the Properties-Based Nesting feature, which allows users to group parts by attributes like delivery date, customer information, or other data, resulting in improved efficiency throughout the production process. This new capability not only organizes parts for better packaging and assembly but also offers flexibility to separate or mix groups, with options to insert remnant lines to facilitate cutting. The new Import Assistant allows filtering layers in DXF/DWG files, as well as deleting unnecessary geometry during files importation significantly reducing manual cleanup and accelerating the preparation phase. Additionally, the Punch Swap in Turret Configuration solves turret limitation challenges by enabling users to apply rectangular and square punches on operations made with tools of different sizes, even when they are loaded at other angles, ensuring smoother operations without the need for time-consuming workarounds.

CAD/CAM 3D: Lantek Flex3D 

Lantek Flex3D v44 introduces significant enhancements that increase performance, usability, and productivity in tube and profile cutting. Reengineering has been done for both the part import process and job management/saving, which drastically improves performance, offering more agility in the system. For steelwork manufacturing, the introduction of new Split Parts Techniques allows users to choose from Straight, Angle, or Shape Z splits, incorporating welding preparations and gaps to maintain precise dimensions after welding. Additionally, support for robotic cutting heads extends the compatibility of Flex3D for machines with more than five axes, including robotic devices, delivering optimized cutting paths for complex steelwork projects.

Lantek MES 

Lantek MES v44 brings transformative upgrades to enhance shop floor efficiency and flexibility. The introduction of Lantek MES Intralogistics optimizes the flow of raw materials from the warehouse to work centers, reducing downtime and ensuring that materials are promptly available for manufacturing machines. This improvement enhances material traceability and minimizes errors, leading to more efficient operations. The new 3D Operations Finishing feature allows operators to register completed parts directly into the system without complex graphical nesting, simplifying remnant management, especially for manual processes. Additionally, the Advanced Management of Lost Parts provides operators with the ability to quickly rework or recover lost or damaged parts without restarting entire workflows, significantly reducing delays and boosting overall productivity.

Lantek Integra

Lantek Integra v44 introduces enhancements aimed at improving usability, cost management accuracy, and workflow efficiency. The new Files Drag & Drop feature streamlines file management, enabling users to quickly add geometry files or documents directly into Quotes, Sale Orders, or Tracking Numbers, with the system automatically identifying file types and taking the appropriate action significantly improving the speed and ease of commercial processes. Additionally, Material Scrap Price Definition offers more precise control over material cost calculations by allowing users to set specific scrap prices for different materials. This added flexibility ensures accurate, competitive quoting and cost estimation, with the system automatically factoring in scrap costs for each nesting while maintaining full traceability.

Lantek Bend

Lantek Bend v44 introduces powerful features aimed at enhancing automation, integration, and efficiency in the bending process. The Enhanced CAD Import Module now supports a wide range of native CAD file formats and uses the Hoops library to automatically recognize materials, thicknesses, and bending lines, significantly reducing manual input and accelerating the import process. The new Starmatik Export Functionality expands Lantek Bend’s capabilities for robotic programming by exporting bend line data into a DXF format for use with Lantek Expert, for precise and automated programming based on specific material properties. Furthermore, deeper Integration with Lantek Expert, MES, and Integra transforms Lantek Bend into a fully interconnected solution, allowing users to open, modify, and sync 3D files seamlessly across all systems. This integration simplifies data management, provides real-time updates, and improves efficiency across quoting and production, reducing complexity for users of all skill levels while enhancing operational agility.

A Major Step Toward the Smart Factory

Lantek v44 is not just another software update; it redefines how modern manufacturing should operate. The new “Connected. Live. Smart.” concept, combined with Lantek Analytics, offers manufacturers real-time insights and smarter decision-making by connecting machines, operators, and data sources. This powerful tool enhances production efficiency, allowing users to optimize scheduling, monitor performance, and gain complete visibility over their lines.

“Our goal with v44 is to empower factories to become more connected, more efficient, and more intelligent,” says Raúl Chopitea, Head of Product at Lantek.

About Lantek

Lantek is a multinational which is leading the digital transformation of companies in the sheet metal and metal industry. With its patented manufacturing intelligence software, it enables factories to be connected, turning them into Smart Factories. It rounds off its range of services with CAD, CAM, MES, and ERP solutions for companies that manufacture metal parts from sheet metal, tubes, and profiles using any cutting technology (laser, plasma, oxycut, waterjet, shearing and punching).

Founded in 1986 in the Basque Country (Spain), one of the main European hubs of machine tool development, Lantek enables the integration of sheet metal and metal processing technologies using the most advanced manufacturing management software. The company is currently the outstanding leader in its sector thanks to its capacity for innovation and commitment to internationalization. With more than 36,000 customers in over 100 countries and 21 offices in 15 countries, it has an extensive network of distributors with an international presence.

Why OSHA Inspections Matter

OSHA is dedicated to maintaining safe workplaces, and inspections play a vital role in enforcing this mission. Companies in high-risk industries, those with recent complaints, or workplaces where severe injuries have occurred are among those most likely to face an OSHA inspection. Beyond the immediate implications of an inspection, keeping workplaces in compliance with OSHA standards significantly reduces the likelihood of injuries, improves morale, and even enhances productivity.

Preparation Is Key: Laying the Groundwork for a Successful Inspection

Review and Organize Documentation A well-maintained record of safety documentation is the foundation of a strong inspection process. OSHA mandates that employers keep accurate records of workplace injuries and illnesses, including OSHA 300, 301, and 300A forms. Ensuring these documents are current, accurate, and easily accessible demonstrates a commitment to compliance and can make a positive impression on inspectors.

Ensure Training Compliance Safety training, especially on OSHA-regulated topics like hazard communication and personal protective equipment (PPE), is essential. Keep a log of training records that includes dates, employee names, and the content covered. OSHA inspectors will assess these records to verify that training is thorough and frequent enough to mitigate known risks effectively.

Conduct Routine Safety Audits Regular safety audits offer insights into potential hazards and ensure that corrective measures are taken before they escalate. Forming a safety committee or assigning a safety officer to oversee these audits can foster a culture of proactive safety management. Documenting these audits and their findings is equally important, as OSHA inspectors may review these records as part of their evaluation.

Prepare for the Inspection with Mock Walkthroughs Conducting a mock OSHA inspection can identify areas for improvement and highlight any gaps in safety practices. This exercise not only ensures compliance but also familiarizes team members with the inspection process, minimizing stress when an actual inspection occurs.

Understanding the Inspection Process

When an OSHA Compliance Safety and Health Officer (CSHO) arrives for an inspection, they will typically begin with an Opening Conference. In this phase, the CSHO explains the purpose of the visit, which may be scheduled or unannounced, depending on the circumstances. For instance, inspections related to severe incidents or imminent dangers are often unscheduled to capture real-time practices.

Request Identification and Verify the Scope of the Inspection Politely ask the CSHO for identification and ensure their credentials are in order. Once identification is confirmed, clarify the inspection scope, as some inspections may focus on specific hazards, while others may be comprehensive. Designating a company representative to handle communications with the inspector helps maintain organization and control over the inspection process.

Define Internal Roles and Responsibilities Assigning specific roles—such as a point person to accompany the inspector and a record-keeper to document the inspection process—helps ensure that key aspects of the inspection are handled promptly and accurately.

The Walkaround: Ensuring Compliance in Real Time

During the Walkaround Inspection, the CSHO will tour the facility, inspecting specific areas, equipment, and work practices. This stage is critical, as it provides the most direct insight into OSHA’s evaluation of your workplace.

Document the Inspector’s Movements and Observations During the walkaround, your designated company representative should take detailed notes on every area inspected, equipment observed, and any specific safety practices noted by the inspector. Photos can also be valuable for your records, particularly if the inspector highlights areas of concern.

Display Normal Working Conditions Ensure that work operations during the inspection reflect typical conditions rather than adjusting or halting activities. This approach demonstrates transparency and adherence to safety standards as they are practiced day-to-day, which can work to your advantage.

Limit Access to Confidential Areas OSHA allows employers to mark certain areas as confidential if they contain sensitive information or trade secrets. Discuss these designations in advance and inform the inspector of any restrictions, while still accommodating the needs of the inspection.

Handle Employee and Management Interviews with Care Inspectors often interview employees during the inspection process. To facilitate these interviews:

• Educate Employees on Their Rights: Inform employees that they have the right to request a representative, refuse recording, and answer questions without speculation. These interviews offer employees a chance to share their experiences openly, and educating them about the process beforehand can promote a constructive atmosphere.
• Debrief After Interviews: After the interviews, consider holding a brief meeting with employees to review topics discussed, which helps maintain alignment across safety practices.

Addressing Findings in the Closing Conference

Following the walkaround, the inspection concludes with a Closing Conference. During this phase, the CSHO will discuss any preliminary findings, answer questions, and clarify possible violations.

Seek Clarification on Any Observations or Citations It’s essential to ask questions and fully understand any citations, associated standards, and the nature of identified issues. Taking detailed notes during the conference will be valuable if further action is required.

Request Additional Time for Follow-Up If the inspector requires additional documentation or corrective actions, confirm a timeline for follow-up. This request provides a clear path for remedying concerns and completing outstanding requirements.

Post-Inspection: Follow-Up and Record-Keeping

Once an inspection concludes and any citations have been issued, OSHA requires employers to post citations in a visible area within the workplace for at least three days or until the cited issue is corrected. This posting period offers transparency and helps reinforce accountability.

Establish a Corrective Action Plan For citations that require action, creating a corrective plan with clear timelines, assigned responsibilities, and specific steps can ensure timely completion. Document every step taken to remedy each issue, as this information may be reviewed in future inspections.

Document All Follow-Up Actions Each action taken should be documented and stored for future reference. A comprehensive record not only aids in verifying compliance for future inspections but also supports continuous improvement in safety practices.

Maintain an Ongoing Compliance Program Implementing an ongoing compliance program ensures long-term adherence to OSHA standards. Regularly reviewing safety protocols, updating training programs, and conducting frequent audits are key to maintaining a safe work environment. For companies facing recurrent inspections or those in high-risk industries, such measures can significantly reduce the likelihood of future citations.

Leveraging Technology for Compliance Management

Digital tools can streamline OSHA compliance by centralizing safety documentation, tracking audits, and simplifying incident reporting. Companies like VelocityEHS offer solutions that help automate many compliance-related tasks, enabling efficient management of safety protocols and providing real-time data insights. Solutions like VelocityEHS not only support compliance but also empower employers to proactively address safety issues before they result in incidents or penalties.

In Summary

Successfully navigating an OSHA inspection comes down to thorough preparation, clear communication, and responsive follow-up. By maintaining up-to-date documentation, conducting regular audits, and fostering a culture of safety, organizations can minimize disruptions from inspections and focus on long-term improvement. Every step taken toward compliance is also a step toward a safer, more efficient, and productive workplace.

The Evolution of Machine Vision

Historically, machine vision systems were built for controlled environments where consistent lighting and predictable object placement were crucial. As manufacturing environments evolved, these systems struggled to keep up with more complex requirements. AI has reshaped this landscape by allowing machine vision to analyze and interpret nuanced visual data, detecting subtle patterns and defects with remarkable accuracy. Today, machine vision AI systems are capable of learning from vast datasets, adapting in real time, and continuously improving their performance.

One of the most significant advancements is the shift toward edge computing, where data processing happens directly on the production floor rather than in a centralized data center. This setup reduces latency, enabling real-time decision-making for applications like quality control, defect detection, assembly verification, and packaging.

Key Components of Effective Edge Hardware

Implementing a successful AI-based machine vision system requires the right combination of software and hardware. Selecting the appropriate edge hardware is critical, as it serves as the backbone for running AI models and processing large volumes of visual data at high speeds. Here are some key hardware requirements for effective machine vision integration:

• Compute Power and Memory: AI models used in machine vision are data-intensive and require substantial computing power. Hardware equipped with modern CPUs and GPUs, as well as high-bandwidth memory, is essential to support these demands.
• I/O Support: Machine vision systems typically require connections to various cameras and networked devices. Edge hardware should support diverse interfaces to facilitate seamless integration.
• Environmental Protection: Industrial environments can be harsh, with exposure to dust, moisture, and temperature fluctuations. The selected hardware should be rugged enough to withstand these conditions.
• Expansion and Customization: As machine vision applications evolve, the ability to expand and customize hardware becomes increasingly important. Flexible hardware solutions enable manufacturers to scale their machine vision capabilities without extensive reconfiguration.

Scaling Machine Vision with Axiomtek’s IPC962A

One example of cutting-edge edge hardware designed for AI-enhanced machine vision is Axiomtek’s IPC962A, an industrial-grade computer that embodies the necessary robustness, power, and flexibility for these applications. Engineered with the specific requirements of AI in mind, the IPC962A provides manufacturers with a scalable and adaptable solution. Key features of the IPC962A include:

• High-Performance CPUs and GPUs: The IPC962A is equipped with advanced processors capable of handling complex AI algorithms, facilitating fast and accurate image processing.
• Comprehensive Connectivity Options: With multiple I/O ports, this system easily connects to various types of cameras and other devices, supporting extensive machine vision configurations.
• Multiple Display Capabilities: For high-resolution machine vision applications, the IPC962A supports multiple display outputs, allowing operators to monitor and control processes in real-time.
• PoE (Power over Ethernet) Management: The device supports PoE, enabling the connection of cameras and sensors that rely on power through Ethernet cables, simplifying setup and reducing the need for additional wiring.

The IPC962A’s versatility makes it ideal for a wide range of machine vision applications, from defect inspection in high-speed assembly lines to the verification of assembled components. With this solution, manufacturers can leverage the power of AI to achieve a higher level of quality control and operational efficiency.

The Benefits of AI-Driven Machine Vision

By integrating AI at the edge, machine vision systems become highly efficient tools for quality assurance, capable of delivering unprecedented accuracy and speed. The benefits are wide-reaching:

• Enhanced Accuracy: AI-driven machine vision detects minute defects that traditional methods might miss, ensuring consistently high-quality output.
• Reduced Downtime: Real-time processing at the edge allows for instant feedback, reducing downtime by identifying issues before they escalate.
• Improved Traceability: With advanced data collection and analysis capabilities, machine vision systems enable comprehensive tracking and traceability of products, aiding in quality assurance and regulatory compliance.
• Scalability: Edge-based AI systems can grow with the organization, adapting to new products, workflows, and market demands.

Axiomtek: Partnering for Future-Ready Solutions

Axiomtek’s machine vision solutions are designed to meet the challenges of modern manufacturing, supporting Industry 4.0 and smart manufacturing initiatives. With the IPC962A and other offerings, Axiomtek provides a comprehensive solution for manufacturers looking to embrace AI at the edge. Their commitment to customization and customer support ensures that manufacturers can effectively integrate these advanced systems, enabling them to optimize processes and improve productivity across the board.

By combining AI-driven machine vision with powerful edge hardware, Axiomtek is helping manufacturers realize the full potential of Industry 4.0, paving the way for a new era of precision, efficiency, and adaptability in industrial automation.

The WL-300A is a Class 1 laser workstation optimized for working with a wide range of metals (CRS, Copper, and Aluminum). Integrated with a pulsed, nanosecond IR fiber laser (as displayed on the booth), it is ideal for making permanent, machine-readable marks on a variety of materials for tracking and tracing of manufactured components. When integrated with a CW or QCW fiber laser, the workstation may also be used for welding electrical components and is a proven technology for battery tab welding, including dissimilar metals. Standard options include an XY table, rotary stage, cover gas module, fume extraction, bar code reader, and camera systems to tailor the machine to your specific processing needs.

A tried-and-true technology for welding battery packs, resistance welding is often selected for its reliability. On the booth, we will highlight the UB-4000A 200-4000 Amp linear DC resistance welding control that features four feedback modes, precise waveform control, and fast rise time. Weld energy may be programmed in current, voltage, power, or V-A in increments as short as 0.1 milliseconds. This ensures consistent welding conditions and maximum throughput. The power supply will be paired with the TL-188B-EZ pneumatic weld head, which can operate at speeds exceeding 3600 welds per hour. This precise, low-inertia, force-fired weld head has a narrow vertical profile that exerts 5 to 100 lb (22-445 N) of force. With EZ-AIR®, the force supplied is consistent providing additional stability in the welding process.

Also on display will be the MAWA-300B, a pulsed micro TIG welding power supply and torch. The MAWA-300B supplies between 30 and 300 amps of output power and features unique “touch start” and “pulsation” capabilities, allowing a higher level of control as compared to competitive models thus providing more consistent and reliable welds. The model is an ideal solution for EV motor hairpin repair applications for sizes up to 2×4 mm per pin.

There will also be a live demonstration of the new WM-200A IIoT-ready, networked monitor. The monitor will collect high-resolution waveform data from the UB-4000A/TL-188B-EZ, which can be used for instantaneous comparison of good/bad signals, for statistical analysis of the process, and provide a means for manufacturing traceability.

Two other resistance weld monitors will also be featured at the booth: the desktop model MM-400B and the portable, handheld model MM-410B. Both products enable operators to monitor and manage key welding variables that affect weld quality including current, voltage, time, and force. Both units support a range of welding resistance technologies, including AC, DC inverter, AC inverter, transistor, and capacitive discharge. Users can easily navigate the features of each product via an intuitive user interface and touch panel display.

AMADA Press Systems’ ES-1A 48-AXIS CNC Segment-Conductor Coil Processing Machine forms rectangular copper wire into copper hairpins for electric motors. The machine features automatic coil changeover, a tact time of 1.65 s/p, a unique bending sensor system, and a dedicated uncoiler, improving productivity and ensuring stable and accurate bending. Visitors to the booth can speak with representatives and view materials about machine capabilities.

About AMADA WELD TECH

Since 1948, AMADA WELD TECH has worked to achieve one goal: to solve customer’s manufacturing challenges. Knowing there is no one solution that fits all, the company strives to provide customers with innovative and reliable manufacturing technology solutions in an effort to be their single source provider. AMADA manufactures equipment and systems for resistance welding, laser welding, laser marking, laser cutting, hermetic sealing and hot bar reflow soldering and bonding. The company serves a wide range of markets including medical devices, battery, aerospace, automotive and electronic components. AMADA is an ISO9001 certified company.

The five KPIs service leaders need to measure, along with why we need to them differently and how to incorporate Service Intelligence Metrics into your data-driven service organization:

Why Do We Need to Measure Service KPIs Differently?

The service industry has changed dramatically in recent years, and the way we measure success needs to change as well. Here are a few of the reasons why traditional KPIs are no longer enough:

The workforce is changing. There is a labor shortage, and the skills gap between new recruits and retirees is widening. This means that service organizations need to find ways to measure the effectiveness of their workforce, not just their individual KPIs.

Customers are more demanding. Today’s customers expect fast, efficient, and personalized service. Traditional KPIs, such as First Time Fix Rate (FTFR), don’t take into account the customer’s overall experience.

Technology is changing the game. New technologies, such as artificial intelligence and the Internet of Things (IoT), are giving us new ways to collect and analyze data. This data can be used to develop more accurate and insightful KPIs.

What are Service Intelligence Metrics?

Service Intelligence Metrics are a new generation of KPIs that are designed to provide a more holistic view of your service operation. They take into account not just the individual tasks that are performed, but also the impact of those tasks on the customer experience.

Here are five examples of Service Intelligence Metrics:

1. Customer Experience Index (CXI): The CXI looks at service from the customer’s point of view. It considers factors such as quality of service, resolution time, and effort required.
2. Mean Time to Stability (MTTS): MTTS is a measure of how long it takes to resolve a customer issue for good. It takes into account all of the interactions between the customer and the service organization, not just the initial service call.
3. Cost per Successful Resolution (CPS): CPS is a more accurate measure of service cost than traditional KPIs like Cost per Work Order (CPWO). It takes into account all of the costs associated with resolving a customer issue, not just the cost of the initial service call.
4. Mean Time Between Events (MTBE): MTBE is a measure of the average time between customer interactions. It can be used to identify potential problems and areas for improvement.
5. Customer Risk Score: The Customer Risk Score is a data-driven way to assess the likelihood that a customer will experience a service issue in the future. This information can be used to proactively address potential problems and prevent them from happening in the first place.

How to Implement Service Intelligence Metrics

The first step to implementing Service Intelligence Metrics is to identify the data you need to collect. This data will come from a variety of sources, including your CRM system, your service management system, and your customer satisfaction surveys.

Once you have collected your data, you can start to develop your Service Intelligence Metrics. There is no one-size-fits-all approach to this, as the specific metrics you will need to track will vary depending on your industry and your business goals.

However, there are a few general tips to keep in mind:

Focus on metrics that are actionable. The goal of Service Intelligence Metrics is to help you improve your service operation, so make sure you are tracking metrics that you can actually do something about.

Use a combination of quantitative and qualitative metrics. Quantitative metrics provide you with hard data that you can use to track your progress over time. Qualitative metrics can help you to understand the why behind the numbers.

Don’t get bogged down in too many metrics. It’s important to track a few key metrics that are important to your business, rather than a bunch of vanity metrics that don’t provide any real insights.

By following these tips, you can start to implement Service Intelligence Metrics and gain a more holistic view of your service operation. This will help you to improve the customer experience, reduce costs, and achieve your business goals.

By Aquant

Particularly for engineering-heavy industrial equipment environments, these BOMs often have a very complex structure with multiple levels or layers of subassemblies. While the drawings in a CAD or design program handle this easily and natively, the way the full BOM for a top level, finished product is structured in an ERP/MRP system has significant impact on the production of the actual product. Production managers and shop floor workers have to navigate the complexities of a multi-level BOM in real-time as they keep to a production schedule and can get frustrated or overwhelmed dealing with an extraneous amount of paperwork or unnecessary data.

Building a bridge between engineering and production is crucial to maximizing quality without sacrificing efficiency.

Dividing a Manufactured Part into Sub-Parts

The first decision is how to structure the bill of materials within the business system used to run operations, typically an enterprise resource planning (ERP) system, and then determine whether to stick to the complex, hierarchical, sub-BOM (or subassembly) structure or to ‘flatten’ the BOM into a single-layered product.

Take the process of building a custom conveyor system as an example. You could either:

• Create a single BOM that includes the entire system, such as the frame, motor, and belts.
• Or divide it into subassemblies for the frame, motor, and belts, each of which is managed and produced separately before integrating during final assembly.

A flexible, manufacturing-focused ERP will allow for either approach and should provide options for simplifying production even with the complex, multi-level structure.

Either approach results in a functional product that effectively drives inventory, captures cost, and meets specifications. But, often a multi-level BOMs requires the ability to manage suborders and planning for each of the subassemblies, and your production plan and goals must be considered.

If a subassembly must be built discreetly (for traceability purposes), is overbuilt or purchased from a subcontract manufacturer, then the best practice is to maintain the subassembly breakout in a hierarchical BOM. If a subassembly is shared amongst other products in your mix, it is often more efficient to ‘overbuild’ or ‘batch’ build these subassemblies separately, maintaining some kind of safety stock, or building to a consolidated demand through material requirements planning (MRP).

If you are responsible for all production, and these subassemblies are unique to the top level, you will need to consider the implications of the complexity in production. Your production process may be most efficient by processing a flat BOM on a single work order that captures all raw material/component demand and labor for the entire product.

Understanding the Impact of Subassemblies on Production Efficiency

Once the bill of materials is structured within your ERP system, the process of initiating production begins when a work order is issued. A manufacturing ERP system will be capable of recognizing the relationships between subassemblies and the top-level BOM and should provide practical tools to streamline production workflows based on these connections.

A robust ERP, such as Cetec ERP, also offers manufacturers several options for handling subassemblies, ensuring that production planning aligns with operational efficiency and material availability. Typically, manufacturers can choose from the following options when managing sub-BOMs:

1. Create Suborders – discrete suborders under the parent order

This option triggers a work order for each subassembly, linking it to the parent work order. This would typically include tools for maintaining full oversight of the production stages for the entire project, allowing for real-time visibility and adjustments to the schedule and production status. This is particularly beneficial when all manufacturing is in-house and subject to complex, dynamic scheduling needs or traceability requirements.

2. Do Not Create Suborder – defers material planning downstream to an MRP

In cases where subassemblies are outsourced or frequently used across different products, this option allows manufacturers to bypass the creation of additional work orders. The subassembly is treated as a purchased component, simplifying the overall work order structure and allowing production planners to handle demand through MRP processes to consolidate demand for the subassembly and create a work order (or purchase order) only if necessary. This option minimizes disruptions by ensuring that purchased parts are available when needed without triggering unnecessary internal builds.

3. Phantom BOMs – flattens the BOM structure into a single work order

Phantom BOMs (or phantom assemblies) serve as a valuable solution when subassemblies are logically required by engineering for labor and/or materials but present unnecessary complexity during production. This option effectively combines the components, labor, and documents of a subassembly directly into the top-level BOM, treating the subassembly as part of the main product without generating separate work orders. By using phantom BOMs, manufacturers can maintain structured product hierarchies while simplifying the production flow.

Optimizing Sub-BOM Settings for Maximum Production Flow

To further optimize your production, your ERP system should be able to automate these decisions regarding subassembly builds based on real-time inventory levels. If sufficient stock is available for a particular subassembly, the system can automatically opt to not build, preventing unnecessary production orders. Conversely, when stock is low or unavailable, the system should be configurable to allow the switch to create suborders based on the determined shortage for the top-level by calculating the required quantities for production. This level of automation reduces manual intervention, ensuring that production schedules are not derailed by stock shortages or excess.

This approach also guarantees that subassemblies are created or bypassed based on material availability, which not only streamlines production but also optimizes resource allocation, minimizing production delays and material waste.

Leveraging Phantom BOMs for Enhanced Production Flexibility

Phantom BOMs offer a powerful alternative when standard subassembly structures create bottlenecks in production. By integrating subassemblies directly into the top-level BOM without generating separate work orders, manufacturers can simplify workflows without sacrificing structure or traceability.

Consider a scenario where a manufacturer is building an industrial HVAC system that includes several subassemblies such as the compressor, evaporator coil, and blower assembly. Instead of creating separate work orders for each of these components, a phantom BOM allows the manufacturer to group them into the main system’s BOM. The production team can then issue a single work order for the entire HVAC system, which includes all necessary materials for these subassemblies. This approach saves time, minimizes administrative overhead, streamlines the workflow, and ensures that production continues without unnecessary delays or interruptions.

Phantom BOMs preserve the logical relationships defined by engineers while providing the production team with a more straightforward, efficient method for assembling complex products. This flexibility is especially valuable in industries with high complexity, such as aerospace, medical devices, and automotive manufacturing, where product variations and customizations are frequent.

Important Advantages of Phantom BOMs

Phantom BOMs offer several practical benefits that can significantly transform production efficiency:

Reducing Administrative Load: By consolidating work orders, production workers are no longer overwhelmed by an excessive amount of paperwork related to multiple subassemblies. This streamlining allows teams to focus on actual assembly rather than administrative tasks.

Improving Material and Workflow Coordination: Phantom BOMs eliminate the need for sequential builds, enabling the assembly team to work on subassemblies as part of the main build process. This eliminates unnecessary stops in the workflow, keeping production moving at a faster, more efficient pace.

Enhancing Flexibility in the Production Line: By allowing subassemblies to be built along with the top-level assembly, phantom BOMs provide production teams with greater flexibility in scheduling and task prioritization. This adaptability is particularly important in environments where lead times are tight, or product variations are frequent.

Balancing Engineering Complexity and Production Efficiency

Manufacturing companies often find themselves trying to reconcile the detailed, structured approach required by engineering with the need for speed and efficiency on the production floor. Multi-level BOMs are essential for maintaining the integrity of complex product designs, but if not carefully managed, they can lead to slowdowns and inefficiencies in production.

By embracing best practices in BOM structuring, such as automating build decisions and utilizing phantom BOMs, manufacturers can keep both engineering and production teams aligned. A modern ERP system that supports these strategies will enable businesses to maintain detailed product structures while keeping production streamlined and flexible.

With the right tools and strategies, it’s possible to retain engineering precision without bogging down production with unnecessary work orders and administrative tasks. Ultimately, the goal is to ensure that complex products are built with the highest quality while keeping production lean and efficient.

Achieving Seamless Collaboration Between Engineering and Production

An integrated ERP system is essential for bridging the gap between engineering and production, providing the structure and control needed for complex builds while simplifying workflows for production teams.

In the end, it’s about creating a manufacturing environment where both engineering and production can thrive, working in harmony to deliver profitable products that meet both quality standards and market demand.

By Scott Ryan

For More Information

Scott Ryan, Sr. Consultant
Cetec ERP, LLC
Ph. 512-299-9170 ext. 116
E-mail: scott@cetecerp.com
Website: www.cetecerp.com
LinkedIn: https://www.linkedin.com/company/cetec-erp-llc/

In spite of advanced robot technology and almost seamlessly interconnected systems, inaccuracies and deviations repeatedly occur in industrial production. In some cases, minimal material differences or imprecise clamping devices can have a negative influence on the welding result and potentially cause time-consuming rework, costly component rejects, or huge cycle time losses.

Integrators often resort to using optical measuring systems to avoid having to make time-intensive manual readjustments. But laser and camera systems are expensive to buy and maintain, plus require space, which restricts access to the component. Fronius has the answer in the form of high-tech solutions for the intelligent iWave, TPS/i, and TPS/i TWIN welding systems that require neither a camera nor manual readjustment.

Perfect welds one after the other despite clamping and component tolerances

The TouchSense assistance system has been specially developed for fillet welds. Before each weld, the robot automatically touches the sheets being joined at the start and end of the weld. It does not matter whether it is the wire electrode or gas nozzle that makes contact: the signal is always clearly assigned and correctly transferred. The low sensor voltage creates a short circuit when the torch touches the workpiece, which enables the robot to precisely determine the weld position and adjust the welding parameters dynamically. Another helpful feature is the immediate warning issued if a spatter bridge forms between the contact tip and gas nozzle, allowing this to be cleaned promptly to increase precision and quality in production.

WireSense—unique precision thanks to CMT technology

What’s so clever about WireSense is its simplicity. “Adding special controller software to our highly sensitive and dynamic CMT drive turns the welding wire into a sensor that can identify contours or air gap deviations on the component,” reports Philipp Schlor, Strategic Product Manager, Industrial Welding Solutions, at Fronius International. To ensure precision control of the welding wire, the Fronius welding system simply needs to be equipped with a CMT-ready system. The Welding Package, i.e., the CMT (Cold Metal Transfer) welding process itself, is not required.

CMT-ready systems consist of a wirefeeder on a wire drum or wire spool, a wire buffer, and a CMT Robacta Drive, in other words a second wirefeeder on the torch itself. A reversing wire movement, which takes place at around 100 Hz, causes the electric motor in the drive unit to scan the metal surface with the wire. It is this high-frequency scanning of the workpiece that provides the necessary levels of precision. Even if the surface being scanned is uneven, such as the sheets lying at an angle, the edge can still be detected and measured without any difficulty.

Detecting the edge position and air gap height

“Our revolutionary WireSense technology uses the scanning function of the reversing CMT wire movement to determine the exact position of the component and edge as well as air gap heights. Steel, stainless steel, and aluminum sheets from 0.5 to 20 millimeters thick can be scanned quickly and precisely,” emphasizes Schlor. Every raising and lowering operation on the component can be recorded extremely accurately relative to a reference point specified at the start of the scanning process. In just seconds the robot has compared the taught positions with those measured, or in other words it has checked the stored values against the actual position data. If it detects any differences, the course of the seam is adjusted accordingly in the robot’s coordinate system and the weld is produced in the right place.

“WireSense opens up a multitude of possibilities for robot integrators to identify high-quality solutions for challenging welding tasks,” reveals Schlor: “The edge being welded doesn’t necessarily have to be detected. Any fixed reference edge on the component, such as the component edge or a notch, can serve as the starting point from which welding is to take place at a certain distance. This enables even difficult-to-detect parts, like a rounded sheet, to be welded at the desired position.” 

Reliably bridging air gaps

With WireSense the wire electrode becomes a height sensor, allowing air gaps to be determined on lap joints using the precisely measured sheet edge height. To achieve perfect results it is possible to specify in advance which jobs stored on the Fronius welding system should be called up for different air gap sizes. This allows the robot to always respond appropriately and weld with the welding parameters that are ideal for the air gap dimension in question, preventing welding errors and time-consuming rework.

SeamTracking: seam tracking during welding

This assistance system plays to its strengths when it comes to manufacturing railroad or construction vehicles. When thick sheets or long seams are being welded, the heat input can lead to component distortion. To ensure the robot still welds in the right location, a system is needed which reliably detects the welding position during welding, such as on a fillet weld or prepared butt weld.

To do so, the robot moves back and forth between the two sheets during welding. The controller converts the actual values identified into signals for the robot controller. The robot then uses these signals to identify the specified welding position, or possible deviations from it, and corrects the path automatically to ensure welding takes place reliably and in the correct location.

Program robots up to 30 percent faster

The key to high quality lies in teaching the correct welding path. The tried-and-tested TeachMode assistance system helps the welder set the weld seam positions on the robot, making the programming process extremely easy. The reversing wire movement prevents the wire from bending in the event of contact with the component and saves the user from having to remove the deformed wire or re-measure the stickout.

Wire-based assistance systems save time, money, and resources

Using the existing wire electrode as a sensor not only reduces expenditure and maintenance costs for additional sensor hardware, but also frees up space as access to the component is not restricted in any way. At the same time, the Fronius assistance systems cut rejects and time-consuming rework because welding is performed reliably at the correct location. Subsequent re-programming of robot paths is also minimized as the robot can correct the weld seam path by itself. All these factors increase efficiency in production while also reducing the amount of time spent and material used.

In the booth, the company will highlight the WL-300A, a CDRH Class 1 laser workstation optimized for working with a wide range of metals (CRS, Copper, and Aluminum). The enclosure platform is a basis for a range of different processes. When integrated with a pulsed, nanosecond IR fiber laser (as displayed on the booth), it is ideal for making permanent, machine-readable marks on a variety of materials for tracking and tracing of manufactured components. When integrated with a CW or QCW fiber laser, the laser may also be used for welding electrical components and is a proven technology for battery tab welding, including dissimilar metals. Standard options include an XY table, rotary stage, cover gas module, fume extraction, bar code reader, and camera systems to tailor the machine to your specific processing needs.

Known industry-wide for producing reliable, highly durable resistance welding equipment, AMADA will demonstrate its UB-1500A Low Power Linear DC Micro Spot Welder with the SL-321A Light Force Motorized Electromagnetic Weld Head. This product combination was designed specifically for applications requiring precise positioning and force control resulting in the kinds of robust, repeatable micro-welds commonly required in the medical device manufacturing processes.

Complementary to the resistance welding system will be a live demonstration of the WM-200A IIoT-ready, networked weld monitor. WM-200A collects high-resolution waveform data which can be used for instantaneous comparison of good/bad signals, statistical analysis of the process, and provides a means for manufacturing traceability. AMADA will also show a range of other handheld and desktop weld process monitoring solutions to aid in production.

Finally on display is the SIGMA® LS Laser Micromachining Subsystem, a femtosecond laser-integrated micromachining module designed for high-precision processing versatility and straightforward integration. The small form factor makes SIGMA LS ideal for machine builders and system integrators, as well as contract manufacturers, job shops, and R&D laboratories.

About AMADA WELD TECH

Since 1948, AMADA WELD TECH has worked to achieve one goal: to solve customers’ manufacturing challenges. Knowing there is no one solution that fits all, the company strives to provide customers with innovative and reliable manufacturing technology solutions in an effort to be their single source provider. AMADA manufactures equipment and systems for resistance welding, laser welding, laser marking, laser cutting, laser micromachining, hermetic sealing, and hot bar reflow soldering and bonding. The company serves a wide range of markets including medical devices, battery, aerospace, automotive and electronic components. AMADA is an ISO9001 certified company. Contact AMADA WELD TECH at info@amadaweldtech.com.