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This informative blog allows plastics professionals to discuss plastics training and technology. Brought to you by Routsis Training: the plastic industry's premiere training provider.

Automation vs. Robotics…

I was asked the following question by a technician the other day…

Bob
What is the difference between automation and robotics?

My Response
Automation generally refers to any component which performs a basic repetitive task; such as conveying or sorting parts. In general, robotics are more complex devices which are programmed to perform advanced repetitive tasks; such as the removal, stacking, packaging, or assembly of parts.
Additional Thoughts
In the plastics industry, the terms automation and robotics both refer to mechanical pieces of equipment and are often used interchangeably.
-Andy

Broaden the Horizons of Your Employees, Part 2…

I recently received a request from a social-networking site to discuss the complications companies encounter in locating well-rounded employees. In this post, I want to address the underlying problem, which is the lack of comprehensive training for production employees.
Initial Concerns
The most effective training systems provide the employees with (1) the information and skills to work and make effective decisions in their job and (2) prepare them for new challenges and advancement opportunities.
Regarding the second goal, it is critical that you prepare your employees for professional growth and advancement. Once you train your employees enough to become competent and capable at their job, additional training should then be made available.  Although some employees are content in their job, do not assume that your workforce is content to remain in the same job doing the same thing until the end of time. The best scenario is to have a cue of overqualified employees waiting for advancement. If a job is not currently available, many employers will offer them the opportunity to fill in (typically with the corresponding pay differential) when a higher job function calls in sick, goes on vacation, or takes an extended leave. 
Additional Thoughts
Change is can be either slow and gradual, or quick and unexpected. Comprehensive employee training combined with effective advancement training will help you prepare your business for change, new markets, growth, and even downsizing.
-Andy 

Broaden the Horizons of Your Employees, Part 1…

I recently received a request from a social-networking site to discuss the complications companies encounter in locating well-rounded employees. In this post, I want to address the underlying problem, which is the lack of comprehensive training for production employees.

My Thoughts
The most effective training systems provide the employees with (1) the information and skills to work and make effective decisions in their job and (2) prepare them for new challenges and advancement opportunities.
Regarding the first goal, the employees needs to know more that what is ‘necessary’ to do their job. For example, teaching the employee the basic steps in a die change is not effective long-term training. An effective die setter should have a fundamental understanding of many aspects including general safety, job-specific safety, tooling, machinery, processing, and the basic economics involved. Without this strong background, they lack the full knowledge and appreciation to bring true value to the company. Such a trained employee may be very helpful in identifying more efficient procedures, evaluating newer technologies, developing new solutions, and troubleshooting complications when they arise.
Additional Thoughts
It has been said that your workforce is your most valuable asset, yet this is only true when your employees are treated as more than simple robots. Robots who perform specific functions can be easily replaced… competent and capable employees, on the other hand, will help your company improve, grow, expand, and take on new challenges.
-Andy

More About Processing PVC…

I received this follow-up question regarding the processing of PVC…

MT
I would like to know if it is safe to mold parts in PVC and acetal in presses that are next to each other?

My Response
It should be safe to process, but it is critical that you vent the fumes from both machines to prevent corrosion of your equipment. You should also take the time to educate your employees on the dangers of combining these materials.
Additional Thoughts
It is critical that you create a system to prevent any chance of cross contamination. This may be as simple as a color-coded system so that the color of the container matches a panel next to the machine. Personally, I would create a fool-proof system where the container for VC is not compatible with the acetal material delivery system and vice-versa.
-Andy

Caveat Emptor: Selling Older Machines…

I was recently working with a company who had an interesting tale regarding the sale of one of their larger, older, hydraulic molding machines with a very large cylinder clamping unit and corresponding hydraulic reservoir…

Engineer
When we were trying to sell one of these pieces of junk, my recommendation was to drain the oil and sell it for scrap metal or parts. Purchasing then told me they had agreed to sell the machine for a few thousand dollars, hydraulic fluid and all.
note: After a quick calculation, he explained to them that they had just lost money since the value of the hydraulic fluid currently in the machine is worth almost twice the amount they are getting for the machine.
My Thoughts
Although complicated to quantify, most of these older machines are a real drag on the company and their resources. In this case, oil in the machine was more valuable than the machine itself. The machine was being sold because it was slow, unreliable, and wasting resources. It will provide the same drain of resources on the next molder who tries to operate it. Especially when your incorporate the expense of relocating, configuring, and hooking up the machine. In this case, I believe the engineer is right… the fluid should have been reclaimed and  the machine should have been either scrapped or sold for parts rather than be brought back into service.
-Andy