Industry 4.0 is Right Now, and Training Lost is Money Lost.
Schmidt Training and Technology Center is rolling out the 4.0 red carpet, and guess who needs to be on it?
A frontrunner in the nation behind Industry 4.0 training, the Schmidt Training and Technology Center (STTC), a dedicated facility at Reading Area Community College for advanced manufacturing technology in Reading, PA, is ready to position operators and technicians to be solely efficient and effective-no outsourcing.
It is no longer okay to maintain the status quo in industry, and automation is seeing the cyber-physical marriage offering improvements across all areas of industrial processes. Seeing changes in the market and technology and acquiring new machinery to expand business is logical, sound decision-making. But to make life easier and produce more, operators need to understand, operate, and easily maintain equipment. This has been the focus of the training offered at the Schmidt Training and Technology Center.
Historically, big manufacturing revolutions grew the economy. From the steam engine, to the first automated mass production model, to the electronics and IT wave, and onward to the digital revolution, each of these pushed productivity. It is time to press forward into the forth revolution, since short-term solutions are just that—they are short. When growth slows down, the need to review and reinvent speeds up. The fusion of manufacturing and technology is that reinvention.
The George Jetson-esque robots are advanced, but serve to complement workers. These robots need to be programmed, not in some futuristic Jetson world, but for the world right now. With virtual reality colliding with the real word, those boundaries are coming apart at the seams creating what is now known as cyber-physical production systems.
It doesn’t end there. Industry 4.0 can help to enhance product designs and even launch new products. “You don’t know what you don’t know,” stated Bonnie Spayd, executive director of workforce and economic development at the Schmidt Training and Technology Center. 4.0 offers more ability to modify and increase speed-to-market of new goods and services. The idea is to maximize productivity and keep costs down, all while maintaining quality. Automation can also expand product to new geographic markets or allow time for more innovation. For businesses wondering if they need to be “advanced,” the answer is no. The team at STTC works with everyone. Small and medium-sized businesses will not be out of place here.
According to Spayd, businesses should not struggle for the knowledge to implement or adopt 4.0 for their unique needs—big or small. Spayd can easily identify opportunities to optimize their operations quickly and efficiently. Evaluating the existing environment on the floor is the first step towards understanding how prepared the company is for 4.0. To develop and leverage these technologies, Spayd can deliver tailored manufacturing strategies.
4.0 Things to Do at Schmidt Technical & Training Center with Industry 4.0
- 1.0: Work on robots.
It is not just for large budgets either. Organizations of every size can afford robots. In fact, robots reduce costs and new machinery speeds up production. And robots are taking over the procedures that are dangerous and the work that workers prefer not to do. The well-being of workers comes with the territory. Go hands-on with Fanuc industrial robots and fully integrated Motoman robots. Interact with co-bots. Learn how to put in an order right from a phone, even in pajamas from home! Robots are an entire production line. - 2.0: Get a customized schedule.
Imagine training that is available, delivered one-on-one and competency-based. The center’s director puts together a customized schedule. This may be just a weekend or a week on location. The training curriculum caters to what is needed. No nonsense. Just a direct line of what workers need. It is fast-focused to equip the worker. Let’s face it. Workers don’t have much time, but a good use of time, perhaps with a little leisure worked in, is worth it all around. The flexibility cannot be overlooked.
When the content is perfectly optimized for particular needs and workers, the decision is just easier. The kicker is to invest in the training that covers the type of manufacturing that is on the floor. Whether working with a millennial or person who had been around longer and who might have some resistance to the changing technology, the training can be delivered in a way that workers can process and retain. Some workers aren’t used to this technology, but mining their critical thinking skills and shifting the way in which they experience their jobs will empower employees. Their frustrations over not being trained will cease and high job turnover should take a downswing. - 3.0: Save money.
Trouble-shooting and organized problem solving are essential. If a plant cannot produce services and goods, the plant is crippled until production capacity is back up to 100%. “A machine goes down for 10 minutes. That’s costly. But if your people come back with the skillset they need to troubleshoot immediately, things are up and running,” states Spayd. That’s money. Many learning systems feature a computer-based fault insertion system, which automatically inserts faults and tracks trainees' troubleshooting activities.
Equipment and machines need frequent maintenance and care. Every time the system experiences technological problems or needs regular upkeep, a technician needs to be hired. That’s money lost. The line is down too. That’s more money lost. It would be pretty difficult for someone who is not trained to work with 4.0 equipment or an automated machine. But by having an in-house worker able to do those tasks, money can then be used on some other area. - 4.0: Find out what you don’t know.
When is the last time the company brought about an innovative product or considered a new geographic market? Perhaps 4.0 is not even being utilized on the floor? A simple phone call with Spayd is worth the time. Spayd can even take a virtual look around the plant to see what may be needed and what possibilities exist. If an on-site visit is preferred, she can meet at the plant, walk through the floor, and offer up an idea or two.
There is still need for trained people, even though that job may look different with the implementation of 4.0 technologies. This proactive approach confirms that trained people are the next skilled workforce. When the training is competency-based, each worker must be competent in one area before moving to the next. With the technology evolving this rapidly, the way in which workers experience their jobs has changed. The front line workers, not only want, they “need” to be able to troubleshoot and solve problems. Imagine the frustration of not having trained on a piece of equipment. Sure, a maintenance contract likely comes with purchase of automated equipment, but if an actual employee had the capability to troubleshoot that piece of equipment with a smartphone or simple adjustment, why not save that time and money?
With growing demand in dynamic production environments, 4.0 technologies are offering a higher ROI. Making adjustments or performing maintenance on the fly is paying off in dividends. These multi-skill abilities are an investment, not really to be considered as an expense. 4.0 offers more ability to modify and speed to market of new goods and services. The idea is to maximize productivity and keep costs down, all while maintaining quality.
Surrounded by state of the art, industry standard components, and a range of component types, trainees will be using hands-on skills to perform on the same equipment found in industrial and manufacturing floors today. The course content is always customized. Courses are built for 1:1 interaction. That means no long, boring curriculum, no “This takes years to complete,” and finally, no “We’ve already had that training” dissatisfaction. It’s a high engagement program. Executive director, Bonnie Spayd, knows what skills and training programs are needed. She has designed pertinent curriculum and upskilled employees in the areas of robotics, technical maintenance, information technology, precision machining. “Everything we do in the center is applied, so you’re going to learn theory on mechanics or robots. Then we’re going to teach you the applied piece,” stated Spayd. Everyone who actually works at Schmidt, Spayd included, has actually worked in the field of manufacturing. They not only talk the talk, they walk the walk.
Since instruction is mostly hands-on, it drives those theories home. And workers will not be limited to one piece of equipment. There has been a lot of investment into the facilities at Schmidt. Travis Palmer, an electrical instructor at Schmidt, whose experiences in industry include Carpenter Technologies and Boston Beer, said that when people first arrive at Schmidt, “They are amazed at the equipment. They see equipment they’re familiar with being used in the field.” There are 5 separate labs in the building: mechanical, electrical, controls, robotics, precision machining. These labs offer opportunities to apply the theories. Palmer teaches everything from the fundamentals of electricity and how it’s used, all the way to VFDs (variable frequency drives), motor control, wiring, and motor types. Want to know how a DC motor is constructed and wired? He’s your man. Want to know how an AC motor is constructed and wired? He’s still your man. Most importantly, he teaches motor control trouble-shooting so that a trained worker can go to the equipment, mechanically diagnose it, electrically know how to test it, and finally, how to fix it.
Schmidt has a growing selection of courses covering everything from soup to nuts. The mechanical lab offers hands-on training with drives, hydraulics, pneumatics, pumps, piping, and rigging. Hop on over to the electrical lab and workers can learn about AC/DC, motors, sensors, and power distribution. The PLC networking lab features Allen Bradley, process control, and communication. In the smart automation, mechatronics and robotics lab, programming, process control, simulation and communication can be learned, with every lab offering extensive trouble-shooting.
The center is also offering AMIST Level 1,2,3,4 Certificates. These courses provide skills that are necessary for industrial maintenance in manufacturing. Advanced Manufacturing Integrated Systems Technology-Mechatronics AMIST 1 topics include: Basic Hydraulics & TS, Basic Pneumatics, Mechanical Drives 1&2, Electrical Control Circuits, Motor Control, Electro-Fluid Power Electronic Sensors; Residential/Commercial/Industrial Wiring, Power Distribution & Basic AB slc500 PLC Troubleshooting. AMIST Level 2 topics include: Mechanical Drives 3&4, Conveyors, Vibration Analysis, Laser Alignment, Central Lubrication, Int./Adv. Pneumatics, Pneumatic TS, Basic Electrical Machines System, Adv. Electric Motor Controls, AC & DC Electronic Drives, PLC Analog, Data Highway & Panelview. AMIST Level 3 topics include: Process & Thermal Process Controls & Instrumentation, PLC AB Troubleshooting ControlLogix, Analog, PanelView Plus Learning System, Devicenet ControlNet, EtherNet; Automated material handling w/robot interface & Motion Control. AMIST Level 4 topics include: Print Reading, Manufacturing Fundamentals, Project Management, Computer Integrated Manufacturing and Mechatronics Application Project.
But don’t take it from me. Companies that have utilized Schmidt’s training facility have a lot to say. Pat Saylor, maintenance supervisor at the Hershey Company, found, “It’s always been a pleasure to work with any of the staff. We have always worked together and have been provided with what we need to develop our plant needs." Saylor says that his workers gave "all positive feedback” and “learned a lot of new skills and techniques for manufacturing maintenance that they may not have had the opportunity to have done.” Saylor cited the ability to start classes as he hires instead of having to wait on a fixed schedule as being one of his preferred distinguishing characteristics about Schmidt.
Mike Gipe, maintenance training coordinator for the Hershey Company, said, “So far everyone attending is very pleased with the training and grateful to have the opportunity to go there. It is a nice facility that is well laid-out with equipment conducive to training and learning. Everyone that I met on the staff has been very nice and ready to help our students and us (company).”
Situated in a small city surrounded by rich farm county, Schmidt TTC is located in Reading, PA. After training, the Schmidt team will suggest places to explore picturesque Berks County, take in the Arts, check out the local sights, or just enjoy the best local watering hole and restaurant fare. Modern, comfortable, convenient lodging can be incorporated as part of a seamless training package. Schmidt TTC is rolling out the 4.0 carpet.
Industry 4.0 has made a lot of promises. One thing that’s for sure is that it is changing the way workers do their jobs. Give them the skills to thrive in the 4.0 Industrial revolution so that they can build, program, develop, and apply them, so that we can all grow. They need to be on the red carpet that Schmidt has rolled out.