How to implement improvement in your manufacturing operation for higher profitability

When you realize it’s time to make internal process improvements at your company, how do you introduce innovation onto your factory floor? Do you have a system for developing better procedures and workflow? If so, how is it working for you?

A coherent plan for managing improvement can be a powerful tool for transitioning a vision into a strategy, and a plan into proven success. EWI would like to share a new framework to guide your organization toward reaching its improvement goals.

The Manufacturing Improvement Continuum: A Framework for Successful Profitability and Growth introduces a straightforward program for managed improvement. You are invited to view this paper today, at no charge, by clicking the button below.

 If you have questions about implementing your own improvement plans, EWI is here to help. Please feel free to contact Dominic Myers, Innovation Advisory Director, at [email protected] or 716.710.5535 if you’d like to learn more.

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Additive Manufacturing Consortium Summer General Session Now Open for Registration

The general session meeting of the Additive Manufacturing Consortium (AMC), operated by EWI, will be held on August 6, 2020, 10am-1pm EST.

This virtual event will feature tours of two international manufacturing
facilities involved in AM, SPEE3D in Melbourne, Australia, and DMG Mori-Japan.

The meeting will also feature a technical presentation on new metal alloys for use in aerospace applications from ATI’s Greg Brentrup, and NIST’s Brandon Lane will provide an update on the development of open AM processing datasets.

The AMC General Session Meeting is open to the public. For
more information about the event or to register, contact Mark Barfoot, AMC
director, at [email protected]
or 716.710.5597.

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Application of Micro-magnetic Material Characterization for Metal Stamping

In sheet metal stamping, material property variations between batches of an incoming coil can significantly affect part quality and increase scrap rate. This issue is far more pronounced for emerging third generation (Gen III) high-strength steels. Because there are batch discrepancies, major automotive OEMs and tier 1 suppliers are interested in both real-time measurement and capability methods for predicting mechanical properties of material used in several thousand coils annually processed in stamping production lines. The measured coil properties aid in stamping process control, and predictive models are useful in the product design stage for understanding the challenges of batch-to-batch variation.

Since early 2017, the EWI Forming Center has been using a micro-magnetic material characterization system to inspect incoming sheet material properties. This system examines the interrelationship among microstructure, magnetic properties, and mechanical properties, as seen in Figure 1.

Figure 1. Interrelationship of microstructure, magnetic properties, and mechanical properties

When the microstructure varies from batch to batch, both magnetic properties and mechanical properties change. While most mechanical properties need destructive testing such as hardness testing and tensile testing, magnetic properties can be measured nondestructively. With  this micro-magnetic material testing method,  mechanical properties are identified nondestructively using the polynomial equations of the measured magnetic properties. This nondestructive testing (NDT) system is successfully implemented in stamping production lines. 

Figure 2 shows an example application of this system to monitor the yield strength variation of steel strips from a single coil in the stamping facility. The EWI Forming Center and industry partners are applying this NDT system to establish a machine-learning based algorithm for forming process control. 

Figure 2. Application of the NDT sensor to monitor the yield strength of steel strips [Ref. G Dobmann, Faunhofer IZFP]

If you are interested in learning more about EWI’s capabilities and offerings in this area, please contact Hyunok Kim at [email protected].

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EWI welcomes Jeff Ellis as new Ultrasonics Senior Technology Leader

EWI is pleased to announce the appointment of Jeff Ellis as Senior Technology Leader of the ultrasonics group. He is responsible for managing EWI’s plastics technology roadmap, developing strategies for external engagements, innovating new plastics technologies through internal research and development, and ensuring high technical quality of proposals and reports for customer projects.

Jeff comes to EWI with deep expertise in the processing,
structure, and material properties of polymers. Prior to joining EWI, he worked
at Battelle for 11 years, most recently as Senior Research Scientist in the
Advanced Materials group. In this position, Jeff has consulted with many
Fortune 500 companies in consumer products, health care, military, and
automotive, among other markets. His work has been implemented in all phases of
the product development cycle, from ideation of new products to failure
analysis of existing products.

“Jeff’s wide-ranging technical knowledge in the area of polymer science is a perfect complement to EWI’s current engineering capabilities,” said Kelly Jenkins, Chief Operating Officer at EWI. “His past experience in both technology research and client-based project work fit well with our corporate mission of breaking through technical barriers, solving manufacturing challenges, and furthering the success of our customers.”

Jeff is based in EWI’s Columbus office. “I am excited and honored
to join EWI’s outstanding family of exceptional scientists and engineers,” he
said. “I plan to expand EWI’s already diverse capabilities by helping current
and new clients by solving their product related polymer issues.

Jeff can be reached at [email protected].

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EWI Webinar Series on Manufacturing Improvement Continues July 30th

When you are planning for strategic change in your business operations, processes, or product line, it is important to ask critical questions:

  • How do you address a business challenge with the right solution and support it all the way through implementation?
  • How do you implement change effectively and efficiently?
  • Do you have a structure in place that supports your employees while you attain manufacturing improvement?

A process of managed improvement can
be a powerful tool to transition a vision into a strategy or a set of
challenges into goals. It can be, however, a daunting endeavor.

To get some guidance, EWI invites you to join Innovation Advisory Director, Dominic Myers on Thursday, July 30th at 2:00 PM EST for a 45-minute webinar on “The Manufacturing Improvement Continuum: A Framework for Successful Profitability and Growth.” You’ll learn where problems can arise, how to address these issues step by step, and what’s worked for many other manufacturing companies, both large and small. Dominic will take you from vision through implementation to help make your organization’s great ideas a reality.

To sign up for this free webinar, simply click the button below.

For more information, contact [email protected].

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AM Method to Add Conformal Cooling Channels in Injection Molds Saves Time and Cost

EWI recently worked with Action Mold & Machining Inc. to develop an injection mold tool with conformal cooling channels using the AM process laser powder bed fusion. The new tool demonstrated significant cycle time and mold surface temperature reductions. This innovation in tool production could have significant cost- and time-saving impact across all manufacturing sectors.

The details of this project are discussed in a new paper, Reducing Cycle Time Using AM Injection Molding Tool with Cooling Channels.

You are invited to view this paper, at no charge, by completing the form on this page.

Complete this form to download the paper:

To view the paper, please submit the form above.


To speak to an EWI expert about a project, call 614.688.5152 or click here.

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