A Toyota Way Teachable Moment

Toyota | April 24, 2020

A Toyota Way Teachable Moment
On February 1,1997, a fire destroyed an Aisin factory that made the inconspicuous P-Valve, a brake part required for every Toyota vehicle worldwide. Toyota’s policy is to source any critical part from multiple geographic locations, but in this case, 99% of global production of the part came out of this one plant-at that time, 32,500 units per day. Toyota’s vaunted Just-in-Time system meant only two days of inventory were available in total in the supply chain.

In two days, disaster would strike. What happened next was a premiere of the Toyota Way in action. After the fire, 63 different firms took responsibility for making the parts, piecing together what existed of engineering documentation, using some of their own equipment, rigging together temporary lines to make the parts, and keeping Toyota in business almost seamlessly.

The Toyota Way management principles were formalized in 2001, introducing a new house, at a higher level than the Toyota Production System. Continuous improvement and respect for people are the two pillars of the Toyota Way.

Spotlight

This paper is an overview of how digital twins are becoming increasingly common in manufacturing, aerospace and defence environments.

Spotlight

This paper is an overview of how digital twins are becoming increasingly common in manufacturing, aerospace and defence environments.

Related News

Plex Systems Annual Study Finds Only 24% of Manufacturers Globally Have Implemented a Smart Manufacturing Initiative

Plex Systems | May 08, 2020

Plex Systems announced the results of its fifth annual study, the State of Manufacturing Technology. Smart manufacturing, also referred to as Industry 4.0, encompasses the convergence of physical and digital systems, leading to the rise of smart factories. The changes have helped the company achieve double-digit growth, with plans to reach $100 million in revenues in the coming years. Plex Systems announced the results of its fifth annual study, the State of Manufacturing Technology. The study, which was developed with the support of the research and analyst firm LNS Research, found that among global manufacturers only 24% have currently implemented a smart manufacturing initiative. Another 22% are in the pilot stages. Smart manufacturing, which is also referred to as Industry 4.0, encompasses the convergence of physical and digital systems, leading to the rise of smart factories. Smart manufacturers have better control and visibility across their operations than their peers, allowing them to more quickly and accurately adjust to changing market conditions, including crises such as COVID-19. - Jerry Foster, chief technology officer, Plex Systems “While most companies surveyed do not identify as smart manufacturers today, what is encouraging is that we are seeing a growing appetite to adopt smart manufacturing practices. This appetite, combined with an increasingly reliable blueprint for success as demonstrated by industry leaders, indicates that the smart manufacturing movement will only increase from here.” Read more: Accenture's Acquires Callisto Integration, Expands Capabilities to Help Clients Make Manufacturing Efficient In addition to tracking the adoption of smart manufacturing practices, the survey also found that companies that have realized the benefits of smart manufacturing pilot programs achieve this success by: • Clearly defining desired business outcomes. • Identifying the processes, technology and training necessary to achieve business outcomes. • Successfully implementing the technology and driving adoption to fully realize the expected value. Our new research shows that companies successfully transforming into smart manufacturers are building on robust yet flexible business and operational systems. Without an integrated approach to manufacturing software that can deliver a single source of truth, manufacturers will likely find themselves losing the competitive battle for agility and making sub-optimal decisions in siloes. - Matt Littlefield, president and principal analyst at LNS Research For Sanders and Morley Candy, a fine chocolatier, investing in new hardware and software through new production lines, automating packaging processes, and adopting a cloud-based ERP system have given the company greater visibility and control over its operations. This has empowered sales, enabled faster product testing and development, and allowed the company to redeploy its staff to complete higher-value tasks throughout the organization. These changes have helped the company achieve double-digit growth, with plans to reach $100 million in revenues in the coming years. The survey additionally found: • Manufacturers believe future growth will rely on operational improvements, such as cost reductions (37%), increased capacity (24%), and new production initiatives (40%). • In the next 12-18 months, manufacturers plan to fund new production technology (44%) followed by operational systems, such as industrial automation, Manufacturing Operations Management (MOM)/Manufacturing Execution System (MES), and Enterprise Manufacturing Intelligence (EMI) (34%). However, given the widespread impact of COVID-19 since this survey was conducted, we can expect that the pandemic could shift future investments toward supply chain planning technologies. According to a survey conducted by the National Association of Manufacturers from Feb. 28–March 9, 2020, 35.5% of its member companies were facing supply chain disruption. • The three most-hyped technologies are 3D printing/additive manufacturing (28%), followed by machine learning tied with industrial-hardened devices (24%), and blockchain (23%). These findings indicates that while specific applications are seeing success, there is not yet a clear path to their application within manufacturing environment. Read more: Top 10 ways to utilise AI in smart manufacturing About Plex Systems: Plex Systems, Inc. delivers the first smart manufacturing platform that empowers the world’s leading innovators to make awesome products. Plex gives process and discrete manufacturers the ability to connect, automate, track and analyze every aspect of their business-from the shop floor to the top floor-to drive business transformation. Built in the cloud, the Plex Smart Manufacturing Platform includes MES, ERP, supply chain management, Industrial IoT, and analytics to connect people, systems, machines, and supply chains, enabling them to lead with precision, efficiency and agility in an ever-changing market.

Read More

DIGITAL TRANSFORMATION

Fathom Digital Manufacturing Has Completed Its Business Amalgamation with Altimar Acquisition Corp. II.

Fathom Digital Manufacturing | December 28, 2021

Fathom Digital Manufacturing Corp., a market leader in on-demand digital manufacturing services, stated today that the formerly announced business combination with Altimar Acquisition Corp. II ("Altimar"), a particular-purpose acquisition company, has been completed. The company’s merger was completed on December 23, 2021, following approval by Altimar's shareholders. Fathom was once a privately held portfolio company of CORE Industrial Partners ("CORE"), a Chicago-based private equity firm focusing on investing in and expanding middle-market manufacturing, industrial technology, and industrial services firms. The CORE will continue to be the merged business's major stakeholder. Fathom will remain managed by CEO Ryan Martin, Chief Financial Officer Mark Frost, Chief Commercial Officer Rich Stump, and Chairman of the Board TJ Chung, all of whom have extensive expertise in on-demand digital manufacturing services. Fathom provides a broad range of advanced manufacturing services through a differentiated technology-agnostic strategy that emphasizes speed, problem-solving, adaptive technical responsiveness, and manufacturing expertise, enabling businesses to iterate more quickly and shorten product development and production cycles. Additionally, Fathom helps companies consolidate and localize their supply chains due to the move to Industry 4.0, or industrial digitalization, creating enormous development prospects in the fragmented $25 billion low-to-medium volume manufacturing industry. By using its established business strategy, Fathom has obtained new business with significant innovative firms. This new business is helping to increase market penetration for its additive and traditional manufacturing technologies and boost its backlog of business. We are taking this step because we are a strong, profitable company, and believe our NYSE listing will accelerate Fathom’s growth, both organically and inorganically, by using our stock as a currency to advance our M&A strategy and investing in promising new technologies across the industry,” said Mr. Martin. “These new technologies will enable us to serve our target markets with greater efficiency and responsiveness than ever before. Our broad capabilities from rapid prototyping to low- to mid-volume production, proprietary software suite, engineering expertise and comprehensive support system are competitive advantages we expect will enable us to continue executing our strategic plan and deliver strong profitable growth. “Fathom offers an exciting new paradigm – fast, technologically sophisticated, flexible, and geared for rapid growth,This is an opportunity for us to increase our product offerings to better serve our clients and power their accelerating pace of new product development and manufacturing innovation while expanding both our geographic and strategic reach.” -Mr. Chung, Senior Partner at the CORE “With the completion of this transaction, Fathom has solidified its position at the forefront of the fast-growing on-demand digital manufacturing sector,The company’s unique on-demand platform and diverse offerings serve a broad variety of customers, ranging from the Fortune 500 to high-growth disruptive startups, and are perfectly suited to the challenges and opportunities facing manufacturers today. We are extremely proud of the incredible growth and innovation the Fathom team has achieved over the past three years since we initially partnered with the company, and we’re excited to remain Fathom’s largest investor. We are confident Fathom’s solid foundation will enable the company to achieve further success in the public markets.” -John May, Founder and Managing Partner of the CORE. *This press release contains “forward-looking statements” within the meaning of the Private Securities Litigation Reform Act of 1995. Multiple known and unknown risks, uncertainties, assumptions, and other critical variables, many of which are outside of Fathom's control, could cause actual results or outcomes to differ substantially from those mentioned in the forward-looking statements.

Read More

Shapeways, Inc. Scaling Demand on Manufacturing to Meet Varied 3D-Printing Applications

Shapeways | February 11, 2021

- Over a million customers globally use Shapeways' digital manufacturing solutions - Full-service platform produces more than 20-million parts across dozens of industries - Unique applications include smart beehives, rugged device mounts for off-road vehicles, and a hydrometer for brewing craft beer Shapeways Inc., a market leader in driving digital manufacturing, has achieved important milestones in scaling its manufacturing solutions to meet varied buyer requirements globally. To date, the company has produced more than 20-million parts using 10-different printing technologies and 90 different materials and finishes. Over a million customers across 160-countries have selected Shapeways Inc. to streamline and speed up the manufacturing of everything from Personal Protective Equipment (PPE) to combat COVID-19 to 3D-printed prosthetics and the ever-growing list of the unique product range. Miko Levy, chief revenue officer of Shapeways Inc. said, "Shapeways Inc. fosters creative freedom by removing manufacturing guesswork and complexity. Our purpose-built software, automated manufacturing workflows, and quality processes are accelerating success for some truly groundbreaking products." Protecting Bees with 3D-Printed Smart Beehives For BeeHero, smart hives are the key to guaranteeing that bees flourish while improving hive productivity. In the end, the firm depends on sensors and data science to help beekeepers and farmers quickly predict and prevent complications. The sensors in the BeeHero smart system are housed in two 3D-printed halves produced by Shapeways Inc. using Nylon 12 [Versatile Plastic] material and Selective Laser Sintering (SLS) technology for added elasticity, durability, and sturdiness. By leveraging Shapeways' design-for-additive, product development, and digital manufacturing abilities, BeeHero benefits from manufacturing and delivering speed, produces better-quality products as well as simple assembly and installation. Moreover, the materials used were accepted by the bees, which has contributed to successful placements and better-results, as real-time pollination observation is proven to increase crop yields by up to 30% on average. Manufacturing Industrial-Grade - Ruggedized Off-Road Device Mounts When it comes to manufacturing sturdy device mounts that endure the inflexibilities of off-roading, 67-Designs has delivered tens of thousands of quality systems globally. The idea for producing a lasting iPad mounting device originated from the realization that existing solutions were unwieldy, unrealistic, and aesthetically unappealing. 67-Designs designed and Shapeways Inc. then test-printed sample iterations, which eventually led to the making of the production MagMount G3. This high-end device features a magnet array for better iPad placement and attachment for off-road adventures. The association with Shapeways Inc. involves the use of Nylon 12 [Versatile Plastic] material and industrial-grade additive manufacturing to produce a fine solution. The teamwork also backs 67 Designs' desire to develop a greener creation to market while boosting "made in America" goals with avenues for production in local markets. Brewing Better Beer Requires Lightweight, Durable 3D-Printed Parts When it comes to brewing home-based or professional craft beers, there are different techniques, fermenters and apparatus to bring refine quality and taste. At Tilt Hydrometer, what started as a homebrewer's idea has grown into a game-changing experience that monitors beer gravity and temperature in real-time for immediate changes to the fermentation process. After testing with exclusive plastic milling technology, the company enlisted Shapeways Inc. to produce models and final parts at a 10x cost savings. Using additive manufacturing, Tilt Hydrometer effectively covered subtle electronics in flexible, lightweight, and durable plastic material available from Shapeways Inc. in a rainbow of colors for easy multiple-batch monitoring. Thus, tens of thousands of homebrew and professional brewery clients globally now depend on the Tilt Hydrometer and its intuitive mobile app to create ideal brewing circumstances. Expediting Product Creation with End-to-End Manufacturing Shapeways Inc. offers a wide-ranging array of manufacturing abilities to confirm seamless on-demand manufacturing of quality parts, including self-service options and several levels of skilled support. The company's established additive manufacturing proficiency is strengthened by a global network of certified printers, materials, and manufacturing partners. Shapeways' software offers heightened plasticity, with instant price quotes, automatic file uploads, verified printability checks, quality inspections, and accelerated deliveries. As scaling demands intensify, Shapeways Inc. also delivers clients with access to traditional manufacturing offerings, including injection molding and urethane casting services.

Read More