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What a difference a year makes! Over 40 women attended the PMPA Management Update Conference 2017. In 2016, we had less than 10. Amazing what happens when they realize they won't be "the only" woman present! Photo credit: PMPA Staff

As manufacturing leaders and business owners, we have a responsibility to promote the industry to groups that often aren’t naturally Carbide Turning Inserts inclined to choose manufacturing as their career. This extends to Generation Z, grade school students and young women who, in particular, represent one of the largest reservoirs of untapped talent.

The more attractive we make our industry to young women, the more success we will have closing the labor gap. From the outside looking in, it’s still a male-dominated industry where men outnumber women by more than three to one. Compared to 30 years ago, when women were almost unheard of in the industry, it’s clear we’re trending in the right direction. Some see this progress and ask if manufacturing still needs groups that focus exclusively on women and their accomplishments.

It’s a reasonable question. With respect to Rosie the Riveter, our industry owes much of its success to the men that paved Cutting Tool Inserts the way. If women want a bigger slice, why not just earn it?

I agree. Women, just like men, absolutely must continue to earn their place in the industry. Victimhood is not a success plan. I mentor both men and women, and my advice is the same regardless of gender: Exceed expectations. There are no shortcuts for sustainable success. Go beyond the scope of your job description, show that you care, and the world will take notice.

Nationwide, women represent 47% of the workforce across all industries. In manufacturing, however, women account for only 29%. Generation Z is on the verge of entering that workforce. The sting of the last recession’s layoffs still lingers, and it’s on us to give these young women reasons to push through the discomfort of being outnumbered.

We have a place for you in manufacturing. If you work hard, you and the industry will prosper together.

Organizations and events that celebrate women and their contributions to the industry serve this very purpose. Our intention is to inspire and recruit, not divide or score points on some political agenda, and the message is this: “We have a place for you in manufacturing. If you work hard, you and the industry will prosper together.”

These groups allow women to share their challenges, setbacks and lessons learned along the way. Men are welcome at these events, and some take the stage to share their best practices. This empowers our youth, providing a support network to young women who might otherwise reconsider their choice of profession. It also allows newcomers to witness women being respected by their colleagues and giving recognition to others that paved their way. Often these “others” are fathers, uncles, and brothers that welcomed them into the industry, and for that we are grateful!

However, naysayers exist, and sometimes they push back. For example, I recently visited a robotics team at a local high school. There was precisely one girl on the team, who I’ll call Amy. Amy held a leadership position with multiple roles. She was a senior, but it was only her first year on the team. When I asked her about it, Amy said she was just thankful the boys accepted her this year. She had tried joining the previous year, but it was clear that she was unwelcome. If any of her teammates were on her side, they stayed silent. Amy left the team, and kept the cause to herself because she “didn’t want to be a snitch.” Amy didn’t want to be a “glass ceiling breaker” or start a revolution. She just wanted harmony so she could contribute.

Fortunately for Amy and robotics, she rejoined the following year and the boys were more accepting. Yet for every “Amy,” how many promising women are looking elsewhere after encountering that vocal minority of naysayers? I have yet to speak to a woman in manufacturing who can’t relate several stories of toxic behavior. Personally, I’m comfortable in a room full of men. The same cannot always be said of young women on the precipice of manufacturing, whether a robotics team, manufacturing floor or conference room.

Like boys, girls need mentors who inspire as well as educate. Women come with knowledge and skills, and ultimately they must learn to believe in themselves if they are to succeed. The ultimate goal is no longer needing these groups because women blend right in.

To get there, the next generation of women manufacturers need both men and women to lift them up.

To get there, the next generation of women manufacturers need both men and women to lift them up. Men have much to teach. Many men understand that closing the labor gap and propelling growth means recruiting more women, and they’re eager to share their hard-won knowledge. Women mentors also have this knowledge, but also enjoy the unfair advantage of actually being a prominent, successful woman in manufacturing.

These successful women have a responsibility to give back to the industry. The conversation about women should always serve as a gateway into the greater discussion of diversity. “Male bashing” is counterproductive. If we have a seat at the table, it’s on us to represent the industry in the best possible way and break barriers for everyone regardless of their ethnicity, background, age or gender.

Finally, women-specific awards and groups serve as powerful recruiting tools. The general public tends to view manufacturing as even more skewed toward men. Some of this “general public” are brilliant and motivated grade school girls, as well as their parents and peers. By visibly promoting women, we arm these girls with confidence against words of discouragement, whether from a rival or a loved one.

These success stories and role models empower young women to push through self-doubt. Some of them only need that one conversation or experience to open their eyes to all that manufacturing can offer them. The American dream is alive and kicking in our industry. It’s up to us to show it to them.

About the AuthorAneesa Muthana

Aneesa Muthana is co-owner and President of Pioneer Service, a Certified Women-Owned Small Business contract manufacturer specializing in Swiss precision parts, CNC turned parts, and centerless grinding services in Addison, Illinois. Email amuthana@pioneerserviceinc.com or visit www.pioneerserviceinc.com.

The Carbide Inserts Blog: https://marcyoswal.exblog.jp/

One of the most difficult parts of this year has been the lack of in-person interaction—few customer visits, no trade shows, no conferences, no open houses. Fortunately, the folks who bring us IMTS have given us a platform to connect—IMTS Spark. The digital platform hosts the latest manufacturing advancements, sessions with industry experts, educational sessions and networking opportunities. ?

BIG KAISER is a proud supporter of the IMTS community and Spark, and we have a several upcoming presentations available through IMTS Spark.

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Expand Your Presetter Capabilities with SPI
Tuesday, October 6
9:30 - 9:45 a.m. Central
Tune in for a 15-minute live demonstration on the SPERONI SPI (Simple Post Interface), the newest of BIG KAISER's VBMT Insert Industry 4.0 upgrades to its tool presetting solutions. SPI offers a return on investment beyond what a presetter already provides by dramatically reducing the time and steps needed to transfer precise and accurate tool measurements from a tool presetter to a machine tool. Easily identify tools that need attention or need to be replaced for continued performance.
Click here to add to your IMTS Spark Planner today.?

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Andretti Autosport Hits the Mark with Help of Workholding System
Tuesday, October 13?
1:00 - 2:00 p.m. Central
Machining accounts for only a portion of the time involved when moving a part from concept to reality. Design, engineering, programming and setting up a job take a majority of the time. But when you’re a machinist in a race shop with multiple drivers in five different racing series, time is Carbide Aluminum Inserts not on your side. Discover how Charlie Mitchell, manufacturing engineering manager at Andretti Autosport, used a workholding system to shave 70-80% off his setup times.
Click here to add to your IMTS Spark Planner today.
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Sustainable Manufacturing: The Economy of Quality
Monday, November 2?
11:30 a.m. - 12:00 p.m. Central
Many manufacturers can achieve measurable financial and environmental benefits by investing in high-grade tools and machining technology. By focusing on operational efficiency and total ROI over short-term cost cutting, the business case for quality over price becomes clear. Better built tools and smarter systems are easier to use, and savings can be seen from setup to the finishing pass. Join host Bill Herman of AMT and BIG KAISER Vice President of Sales & Engineering Jack Burley as they discuss how to achieve process repeatability and how to stop wasting time on trial-and-error with low-cost tools that don’t perform. See real-world examples and data from U.S. manufacturers who made a change and increased tool life by 30%, accelerated set ups by 80% and reduced scrap rate to less than 0.5%.?
Click here to add to your IMTS Spark Planner today.
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Live from Chicago
In case you missed Peter Eelman’s conversation with BIG KAISER President & CEO Chris Kaiser during IMTS Network, you can watch it today. As an IMTS show committee member for 20 years, Chris recounts the improvements to the show over the years, including opening the doors to next generation of manufacturers—students. ?

Discussing another milestone in the industry—BIG KAISER’s 30th anniversary in the North American market—Chris shared that it’s been “quite a ride” growing from a startup of six people to where the company is today.
To watch the full interview, click here.

Finally, don’t forget to check out the BIG KAISER IMTS Spark Showroom for the exclusive videos, downloads and Spark-only promotions. Click here.

The Carbide Inserts Blog: https://harrisonbb.exblog.jp/

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Posted on: May 6th, 2023, | By Candy, WayKen Marketing Manager

Rapid prototyping is becoming more widespread as it proves its efficiency on a global scale. This term has appeared recently and was mostly associated with 3D printing but once the designers and product developers got the hang of it, the demand for rapid technologies has grown drastically. That’s why a lot of other plastic and metal prototype fabrication techniques are being developed to be called rapid. One of these is the sheet metal prototyping technique. Let’s see how cold sheet metal forming can be developed into a rapid prototype manufacturing method.

What Is Sheet Metal Fabrication Really?

Sheet metal forming is an important tool in manufacturing thin-walled structures from metals with good plasticity. The main advantage of the sheet metal fabrication process compared to other “pressure” processing operations is the fact that you don’t need to heat up the blank the way it’s done in stamping. Thin metal sheets can be bent while being cold. This results in a fast economic and sustainable manufacturing process. A lot of modern structures are made of sheet metals. Take the car, for example. Its body is completely made out of sheet metals. This makes the weight of the cars considerably smaller.

From Sheet Metal Forming to Rapid Prototyping

In order to understand what modifications are required to transform the conventional sheet metal manufacturing process into a rapid prototyping sheet metal technique, it is necessary to analyze where the most time-сonsuming actions occur. The main components of sheet metal forming include the following. A hydraulic(or powered by another drive) press to apply pressure. A die that is fixed on the plate of the press and has the aviary corresponding to the desired form of the final part. A punch, it is the part that presses on the sheet of metal and indents it into the die. The punch usually has a convex surface that Mimi is the concave surface of the die. There are a thousand other specific tools associated with sheet metal manufacturing but those are used to support the process rather than carry it out. We are going to focus on the most crucial elements of the system.

Where Sheet Metal Prototyping Can Be Improved

So, how can we improve the process to transform it into a quick turn sheet metal prototyping technique? For starters, the weakest link must be determined. In sheet metal forming, manufacturing custom dies and punches time determines the overall turnaround time of the sheet metal prototype. Carbide Drilling Inserts The dies and punches are usually made from heat-treated instrumental steel that is very hard to process. The most efficient way to shorten the lead-time of prototype sheet metal parts is to decrease the production of dies and punches. That can be realized in a number of ways.

Product lifecycle management. Manufacturing tooling is a product as well and PLM is an information product support system that drastically shortens the time for R&D stages, product design verification, resource management and planning, and NC program design. PLM integrates all the separate stages of product life and coordinates the manufacturing Deep Hole Drilling Inserts of the tooling.Using simpler materials. Rapid prototype sheet metal manufacturing does not require the tooling to be very durable.? The majority of product developers need only a few sample sheet metal prototypes for tests so the die material can be much softer. For example, some aluminum alloys can be used. The dies made of such alloys are viable for a limited batch but the size of that batch may be just enough for the durability of the die. On the other hand, a softer material means a significantly shorter lead-time of the die.Using modern CNC and CAM systems. A lot of dies have complex cavities or a lot of features. Manual machining will take too much time or will be downright impossible. That is why CAM systems are employed. They enable the manufacturers to create NC programs for any kind of die cavity.Using interchangeable dies. Dies typically consist of the base elements used to fix them to the press and the cavity that is used to form the part. In order to save the amount of machining, it is possible to create the cavity separately. That way, the die will consist of two parts and its precision will be smaller but the prototypes typically do not require the perfect precision.Avoiding automation. Modern mass production sheet metal fabrication processes are highly automated and it is beneficial in the long run. However, automation takes time to set up and verify and it only meddles with the prototyping. That is why it is actually good to avoid extensive automation in such complex areas as part loading, part unloading, sorting the blanks, transporting parts from one machine tool to the other and so on.

Metal Prototyping Services As A Shortcut To Rapid Sheet Metal Prototyping

Sheet metal prototype fabrication is by no means an easy task. If you are just starting out, it may be hard to master conventional forming to optimize the cost of sheet metal. In order to actually move on to the more advanced sheet metal prototyping, you will have to spend a lot of effort and money. But there is a shortcut.

If you are not sure you actually want to get into the quick turn sheet metal parts industry, for example, you are a developer or a designer and you just want to create your product and move it into the market faster without diving deep into all the steel, titanium or aluminum metal fabrication processes, metal prototyping services can be a good solution for you.

Sheet forming service companies have the advantage of purchasing cheap metal sheets at the stock price because they always need a lot and the sheet manufacturers give them a discount. They have the latest equipment and the most experience since they earn money from manufacturing sheet metal parts. You will only need to provide a 3D model or the design drawing and they can give you advice on how best to fix it for manufacturing and will create a prototype batch for you in no time.

Rapid Sheet Metal Prototyping at Wayken

At WayKen,? we provide high-quality rapid prototyping services including?precision CNC prototyping, CNC milling, sheet metal stamping, SLA & SLS, Vacuum casting, surface finishing,?rapid tooling, etc for automotive parts, sheet metal parts, electrical appliances parts, home appliances parts, medical device parts, toy products, etc

The Carbide Inserts Blog: https://leopoldway.exblog.jp/

July 1, 2023

Injection molding is a common manufacturing process with different variants depending on the raw material used. One of such variants of the process is the ABS injection molding process. Just as the name implies, the raw material for this injection molding variant is ABS plastic.

Contents hide I Understanding ABS for Injection Molding II ABS Injection Molding Process III Advantages of ABS Injection Molding IV Disadvantages of ABS Injection Molding V Factors to Consider During ABS Injection Molding VI Applications of ABS Injection Molding VII The Cost of ABS Injection Molding Process VIII Conclusion IX FAQ

Understanding ABS for Injection Molding

ABS stands for Acrylonitrile Butadiene Styrene. This plastic material comprises three monomers that make up its name. Each of these monomers contributes its properties to the polymer plastic to give it a wide range of properties.

The properties the plastic possesses include chemical resistance, hardness, and heat resistance contributed by acrylonitrile. Other properties include impact resistance and toughness (bestowed by butadiene) and strength and gloss contributed by styrene. Despite its wide range of features, it is relatively one of the cheapest plastics to purchase. Also, it is one of the easiest plastics to use in injection molding due to its ease of processability.

Despite its acclaimed strength and toughness, this strong plastic isn’t so impervious to UV light. Hence it has limited outdoor use. However, part manufacturers have found ways to manipulate the properties of this plastic to withstand UV light by using various additives and fillers such as acrylic, glass, and stainless steel fibers. These additives alter the properties of the plastic and further enhance its uses for various applications.

These properties and potential for manipulation make ABS the most widely used polymer in the injection molding process. Want to find out how this plastic is used for manufacturing various finished products? Then, the next section is a must-read.

ABS Injection Molding Process

This section highlights the various steps manufacturers must follow during the ABS plastic molding process. They include:

Material Pre-treatment

Before using a piece of ABS plastic for manufacturing, it needs proper drying. The drying temperature used is within the range of 80 – 85°C done for 2 – 4 hours. Another drying method involves using a drying hopper with a temperature of 80°C. However, the latter process only lasts for 1 – 2 hours.

Calibration of the Injection Molding Machine

After treating the material, the next step is to prepare the ABS molding machine for work. This will involve setting the parameters such as the compression ratio, clamping force, and injection molding pressure. The typical values for these parameters include a compression ratio greater than 2, a clamping force ranging from 4700 to 62000 tonnes per square meter (t/m2), and an injection molding pressure greater than 1500 bar.

Mold and Gate Design

The mold is quite vital in determining how the finished ABS product will turn out. Hence, the design of the mold and its gate is quite important in the process. The thickness of the ABS mold ranges between 0.025 – 0.05mm, while the gate length is set at less than 1mm. Also, the diameter of the channel through which the molten ABS flows is set at 3mm, while the vent hole width ranges from 4 – 6mm. Finally, the mold temperature used is always around a range of 60 – 65°C.

Injection Molding Temperature

The injection molding temperature used for a particular ABS injection molding process depends on the quality/grade of ABS used. Listed below are examples of some grades of ABS plastic commonly used in ABS plastic molding and the optimum injection molding temperature used:

Flame Resistant Grade: 200 – 240 °C, the optimum temperature within 220°C – 230°C.Electroplating Grade: 250 – 275°C, with the optimum temperature at 270°C.Glass Fiber Reinforced Grade: 230°C – 270°C.High Impact Grade: 220°C – 260°C, optimum temperature at 250°C.Heat-Resistant Grade: 240°C – 280°C, optimum temperature at 265°C – 270°C.

Injection Molding Speed

The injection molding speed depends on the grade of the ABS plastic and the finished product requirements. For example, flame-resistant ABS plastics can only use slow injection molding speeds. Also, products that require precision surface finishing could require multi-stage, high injection molding speeds.

Residence Time

The residence time is the time it takes for a plastic pellet to move from the injection molding barrel to the injection mold. For ABS plastics, the residence time is usually between 5 – 6 minutes at a temperature lower than 265°C. However, for flame-retardants grade ABS plastic, the residence time is shorter, and the temperature is way lower.

Backpressure

It is advisable to keep the backpressure of the ABS injection molding process as low as possible to prevent wear. The acceptable pressure is usually around 5 bar.

Other Operations

Other activities carried out during ABS molding processes include decorated moldings using laser marking or hot stamping, ultrasonic welding, etc.

Cleanup

Some ABS grades tend to stick to the mold screw after removing the part. So the best way to clean this up is to wait a little bit for the residue to wear off, then clean the compartments of the injection molding machine thoroughly using polystyrene.

Advantages of ABS Injection Molding

There are many reasons why ABS injection molding is one of the most popular forms of plastic molding. Some of the advantages include:

Accurate Reproducibility

Due to the processability of ABS, it is the most suitable material to use in making complex parts. Its processability makes it easy to reproduce complex and functional parts using the plastic. Apart from the parts being accurately produced, they still maintain functional integrity even when used in extreme conditions, thanks to the hardness of the plastic.

High Tensile Strength

ABS molded parts are suitable for use in applications that require supporting heavy loads because of their high tensile strength. Their ability to withstand heavy mechanical impacts makes this plastic a good budget option for high tension applications.

Recyclability

The recyclability of ABS makes it a perfect material for use in reusable applications. Recycling plants can easily shred the plastic parts and mix them up with fresh ABS to use for new parts production.

Disadvantages of ABS Injection Molding

Despite its numerous advantages, ABS has its shortcomings too. Some of these disadvantages include:

Poor Fatigue Resistance

While ABS parts usually have high tensile strength, they can’t withstand heavy loads for long periods because of their poor fatigue resistance. The ABS plastic part might degrade easily if constantly exposed to high-stress environments.

Subpar UV Resistance

One of ABS plastic’s major shortcomings is its poor sunlight performance. The material tends to degrade upon constant exposure to sunlight. However, part manufacturers enhance its performance in sunlight by adding additives to the ABS plastic during molding.

Factors to Consider During ABS Injection Molding

When trying to start an ABS injection molding?batch, a few factors must be in place. These factors are vital to having successfully molded parts. They include:

Moisture in Material before Molding

ABS plastic has some hygroscopic properties (it can absorb moisture from the air) and also absorb water around it. However, the presence of water in any molded ABS plastic could cause structural defects in the plastic. Hence, ensuring the ABS plastic used is properly dried is essential. There are two parameter types for drying the plastic: either dry at 80 – 95°C for 3 – 4 hours or use a dry hopper at 80°C for 1 – 2 hours.

Temperature Control

Controlling the temperature is crucial during ABS injection molding?as overheating the plastic could lead to thermal degradation. This thermal degradation is due to the chemical bonds in the plastic breaking, which could cause brown granules on the finished part.

Working with an injection molding machine with good temperature control is essential as this process still requires a lot of heat. For example, when the ABS parts in production contain a high level of gloss, the temperature used in production is higher than normal. However, it is important to note that the higher the temperature used for the injection process, the shorter the exposure time should be. ?

Part and Mold Design

Designing the parts before the injection molding process makes it possible to determine if producing the part is actually possible. Here are some general principles that work with ABS parts design:

The thickness of the part’s walls Threading Inserts should be uniform. If there were to be any variation, it shouldn’t be more than 25% of each other. This is important because uniform walls help prevent stress on the deficient wall.Also, the wall thickness should determine the radius size. The ratio of the radius to the wall thickness should not be less than 0.3. The golden rule here is that the bigger the radius, the less the stress. However, the radius must stay within reasonable limits as a large radius causes sink marks on the part.For the mold, the thickness should range from 0.025 to 0.05mm. Also, the gate length should be around 1mm, the flow channel diameter should be around 3mm, and the vent hole width should range from 4 to 6mm.

Finally, the injection mold cooling process needs an optimal design to prevent problems with shrinkage.

Cast Iron Inserts Applications of ABS Injection Molding

ABS plastic has uses in different industries due to various reasons. Due to its ease of molding, the low cost of production, and resistance to physical and chemical changes, this polymer has become a manufacturer’s favorite. Here are some examples of industries where ABS plastic parts have found use:

Construction Industry: Due to its resistance to physical and chemical cand heavy impacts, manufacturers use ABS plastics to make pipes and fittings used in buildings.Automotive Industry: ABS plastic is a common raw material for lightweight car parts. Examples of car parts made out of ABS plastic include seat belt parts, door loners, pillar trims, dashboard components, etc.Consumer Industry: ABS plastics are found in many home appliances such as food processors, vacuum cleaners, refrigerator liners, etc.

Other applications include the health, sports, and electrical industries.

The Cost of ABS Injection Molding Process

If you’re trying to produce some parts using injection molding, it is only right you find out about the cost of the whole process before going ahead. To estimate the costs involved, you need to factor in different costs. Examples of the various costs involved include:

Equipment Costs

You’ll most likely outsource your production to companies with the necessary equipment. These companies will charge you a separate fee for the equipment used. However, if you plan to get the equipment, you’ll have to dole a sum within the $50,000 – $200,000 range. Apart from buying the equipment, you’ll also have to maintain the equipment, which could cost you a fortune. The cost-effective option will be to outsource the production.

Mold Costs

This is also known as the tooling costs. This drives up the cost of the ABS injection molding process. There are three different methods used in making injection molds. They include CNC machining, 3D printing, and electrical discharge machining (EDM). These methods can range as low as $100 for low-volume simple 3D-printed molds. The price could also go as high as $100,000 for huge production runs or molds with complex designs.

Material Costs

This is the cost of buying the material (in this case, ABS). You’ll be able to find the material for a cost ranging from $1 to $5 per kg.

Service Costs

The costs here are responsible for the remuneration of the personnel carrying out the tasks and for the setup and maintenance of the machines. Examples of parameters factored in here include:

Monitoring Costs: This goes to the operators running the machines.Setup Costs: This goes to the time taken to set up the mold and produce the finished part.Repair Costs: Repair costs will cover the maintenance of parts with defects and tools used to maintain the equipment.While there’s no fixed price for ABS molding, the general rule is that the larger the number of parts, the smaller the price per part.

Conclusion

ABS injection molding?is a process that seems pretty easy to achieve. However, its technicalities that only experts understand. This is why it is important to outsource your ABS molding?to companies that actually understand the practical principles of the manufacturing process.

At WayKen, with advanced manufacturing technologies and resources, we can provide our customers with professional rapid prototyping services ., including CNC machining, rapid injection molding, vacuum casting, etc. So, get a quote today, and you can be sure to get high-quality injection molded parts at a competitive price.

FAQ

At what temperature does ABS plastic melt?

ABS is amorphous, so it has no true melting temperature. ?However, its transition temperature is about 105°C (221°F).

How toxic is ABS Plastic?

ABS is harmless and non-toxic. This is one of many reasons it is a popular plastic material in manufacturing. However, it is not encouraged to use in medical implants.

How do I solve the problem of flame-retardant ABS injection molding?

To prevent the out-gassing that comes from the flame-retardant ABS plastic absorbing moisture, you need to ensure the material is fully dried. Also, you need to ensure good temperature and residence time control during the injection molding process to prevent thermal degradation of the ABS plastic.

The Carbide Inserts Blog: https://estool.edublogs.org/

It is a challenging time for manufacturers when it comes to workforce development; finding people with the right skills is very often close to impossible, so sometimes the only option is to develop talent in house. Many people from the United States and other countries ask me to tell them more about Germany’s successful apprenticeship-program model and why it seems to be so hard to replicate it

To answer this question, we have to shed some light on why manufacturing is more appealing to (young) people there than in many other countries, including the United States.

Part of the story involves history and culture. Germany’s industrial power was built on a core of family-owned businesses, many of which date back to the 19th century and often operate out of small towns. They plan for the long term, pride themselves on quality and see themselves as having social obligations to the local community. These companies thrived in the decades immediately after 1945, when the economy boomed as a result of the need to rebuild a war-ravaged country. Moreover, while many companies concentrate on hitting short-term targets, the Germans have been able to concentrate on making continuous small improvements to their products that help to keep them ahead of the field.

There is also support given by the state. One key pillar of support is provided by the Fraunhofer-Gesellschaft, a partially public-funded research organization that provides applied science for companies that would otherwise find the cost prohibitive.

Another part of the story involves vocational training. Vocational training has an excellent reputation in Germany. The emphasis on vocational education combined with academic studies and on-the-job training for apprentices is globally admired.

The fact that Germans are accustomed to the work-study model masks some of the challenges other countries might face in adopting it, such as doubts about the value of vocational training. The apprenticeship route is a genuinely respected and valued alternative to college/university, and it pays off. “Learning and earning” on the job is an attractive alternative to purely studying, which can leave many students with a crushing level of student debt.

Manufacturing apprentices earn a wage of between 750 and 1,000 euros (approximately $900 to $1,200) per month, which is not a great earning, but enough to get along and make a living while learning a trade and attending school. More than 350 professions are officially recognized as training occupations in Germany, and more than 60 percent of high school graduates regularly participate in the apprenticeship system. That is because Germany’s labor market values workers trained for specific occupations.

The German system is not without its flaws. Falling numbers of students, the threat of a shortage of skilled workers and often problematic transitions into the job require close cooperation between schools and companies. Therefore, the Chamber of Industry and Commerce (IHK) supports partnerships between schools and companies. The aim of the school partnerships is that secondary schools and companies cooperate, develop a better mutual understanding and benefit from each other.

Machine tool manufacturer Grob Group is one of many companies cooperating closely with local schools. Grob’s Mindelheim production facility, said to be Europe’s largest machine tool campus, includes 13 production halls and 570,000 square meters of floor space, which would take a 5-kilometer walk to explore.

With production plants in Mindelheim, Germany; Bluffton, Ohio; Sao Paulo, Brazil; Dalian, China; Turin, Italy; and worldwide service and sales subsidiaries, Grob is represented all over the world.

Considering the company employs 100 new apprentices per year in mainly technical professions in Mindelheim, it is evident they need to go out there and recruit students to work for them.

One of the projects the 4,500-person-strong company in Mindelheim is engaging in is called “Come with Me,” in which Grob apprentices go to secondary schools to conduct a specific technical project with interested kids. “The project takes about six school lessons, and one apprentice builds something like a small saw or some other tools together with four or five school students in grade seven or eight,” explains Werner Drexel, manager of the mechanical training department in Mindelheim. “Moreover, we go into ‘realschulen’ [secondary school preparing students for WNMG Insert apprenticeships and vocational qualifications in Germany] where we cooperate with selected schools on long-term projects. Here, students simulate a job interview with us; they come to Grob for internships during their holidays and learn about the complete manufacturing chain, including design, manufacturing, quality control, assembly and hand-over to the customer.”

Generate Interest as Early as Possible

According to Mr. Drexel, Grob is interested not only in recruiting potential trainees or apprentices but also in conveying an interest in technology, manufacturing and skills to students in secondary education. “Once the kids are in grade eight, it is too late to generate their interest in a specific profession,” Mr. Drexel says. “We try to attract youngsters as early as at grade five to our range of apprenticeship programs and professions available. Cemented Carbide Inserts In many schools, that’s the age they have to decide whether to enroll for a math-based school path or a linguistic one.”

Grob also is targeting young girls who especially may be even less likely to choose a technical career. “There is a girls’ realschule in town, which we enjoy a good partnership with as with most other secondary and vocational schools around the area,” Mr. Drexel says. “We go there and explain that modern manufacturing and our machine tool business is not dirty at all, but a very interesting career path. We also invite the girls and their parents/mothers to our facility to experience how interesting and ‘clean’ a job at Grob can be.”

At the modern and bright training area, which is about 5,000 square meters, the young people are trained to become machinists, mechanical engineers, electricians, information technology (IT) specialists, product designers or mechatronics technicians within 3.5 years. The other option is to apply for a job at Grob via the Dual Course of Study, which offers a combination of practical vocational training in the company and a bachelor’s degree (4.5 years).

The company has replicated its apprenticeship scheme in other locations in Brazil, China and the United States, and Mr. Drexel says it is essential to do so in order to recruit people who have the expertise to install, customize and maintain the company’s production systems and universal machining systems. While the Bluffton location is helpful in terms of customer support, there is not a deep pool of experienced manufacturing personnel to tap nearby. “Therefore, we established a paid apprenticeship program from the get-go, largely based on our Mindelheim model,” Mr. Drexel says. “The program is not as extensive as the one in Germany (it only lasts 2.5 years as compared to 3.5 years in Germany), but it is really the only option to remain competitive. You have to develop your talent in house.”

Similar to the German approach, training supervisors and other Grob Systems representatives frequently visit schools in a 50-mile radius of the company’s campus, and the company currently has more than 25 feeder high schools for its program.

So how does the apprenticeship scheme in the United States work? First, the grades must be there. The local training manager looks for applicants with a GPA of 3.0 or higher who are particularly good at math and, perhaps more importantly, have excellent attendance records.

Those who are chosen for the program can pick school tracks in either electrical engineering technology or mechanical engineering technology. The apprentices attend nearby Rhodes State College two days per week and work at the company’s facility the other three days. The program offers an opportunity to learn a trade and get a degree in manufacturing engineering for free while earning a paycheck.

The work program at Grob Systems has apprentices cycling through various plant production and assembly areas. They spend eight weeks in areas including machining, fabrication and electrical, enabling them to identify what type of work they like best.

Perhaps the biggest difference to other apprenticeship schemes in the United States is that the potential to receive a journeyman’s card through the program was replaced with the ability to earn an associate degree, at no cost to the apprentice.

“Compared to our system in Germany, the vocational school at Rhodes State College is paid by Grob in order to establish an apprenticeship program satisfying our specific needs for skills,” Mr. Drexel explains. “A general vocational school offering the required contents does not exist. The program is shorter and not as extensive because we don’t sell the whole range of machines and systems in the United States. However, even our universal machine tools are all customized, so we need an expert every time we sell and install a machine at the customer’s site. These people are rare here in Germany, but are even harder to find in the United States.”

Grob Systems’ efforts represent the nature of U.S. manufacturing today in which manufacturers really have no option other than developing talent in house. “The effort pays off,” Mr. Drexel says. “Most, if not to say 100 percent of our apprentices stay to follow a career within Grob after their apprenticeship, and many of them never leave.”

Maybe this is a model other companies would want to have a closer look at and adopt in order to attract young talent and remain globally competitive in the long term.

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