Author: GTI Staff

With new technology and an evolving global economy, it’s imperative that manufacturers stay apprised of the latest in manufacturing technology trends. While manufacturing is outpacing the average growth for the global economy, some companies are still struggling with labor shortages, fluctuating supply logistics, and advances in predictive maintenance. As technology changes, manufacturing must change with it, and understanding the technology trends of the manufacturing industry is key to avoid being left behind.

Agriculture & Construction are Using Robots
A recent manufacturing study reported that over 80% of companies listed workforce issues as one of their top three challenges facing their business. Despite record growth rates, manufacturers are still struggling to attract and retain top talent. The industry hasn’t been able to maintain the allure and sense of stability that it had decades ago, and competition overseas has driven wages down. To get around this issue, agriculture and construction companies have begun to develop robots and other complex machines to fill in the labor gap. With industries more and more dependent on autonomous robotic technology to produce goods in a timely manner, it is essential to have an independent repair service that is well versed in the most advanced technologies to minimize downtime.

Aerospace is Investing in Artificial Intelligence
With an estimated $8.7 trillion in economic output over the next ten years, aerospace is growing at an impressive rate. Increased dependence on air travel and advances in aerospace and materials engineering are some of the factors that have contributed to the growth of the industry. However, recent studies show that the sector’s investments in artificial intelligence programs are the real secret weapon for airplane manufacturers–which is why the total spend on machine learning programs increased by over 75% in 2018.

The reason for this development is the necessity in minimizing both machine breakdowns (which can mean loss of life when you’re talking about airplanes), and the high cost of conducting unnecessary repairs. It costs a fortune for an airplane to be taken out of operation for unnecessary maintenance. Artificial intelligence programs can collect data and make predictions based on the real-time health of the machine to accurately and safely optimize equipment repairs. Utilizing third-party repair services that can implement data from predictive maintenance programs, is key to cutting costs in the long run.

Manufacturers are Using Cloud Storage to Optimize Supply Chain Management
One trend that has been consistent across all industries for many years, is the increased reliance on the Industrial Internet of Things (IIoT) to collect and interpret data from multiple sources simultaneously. Manufacturers have primarily been using data stored and analyzed in cloud programs to schedule repairs and reduce maintenance costs. This has proven to be an effective way to cut down on the expensive practice of running machines until they break, or following manufacturer recommended repair schedules that tend to be overly-cautious.

Recently, many manufacturers have taken the information gleaned from IIoT devices a step further by utilizing the data collected to optimize supply chain management practices. In a global economy, the cost of producing too much or too little adds up. From storage and material costs to customer turn-over, it’s essential manufacturers are able to accurately estimate and meet their demand needs. Utilizing data about machine health and longevity allows manufacturers to schedule repairs for lower demand time periods in order to optimize machine performance in peak seasons. Working with repair services that know best how to optimize data from IIoT devices is essential to get the most of these benefits.

If you are in need of a cutting-edge spindle repair service to stay apprised of all the advances in manufacturing technology trends, contact the professionals at GTI Spindle today.

About GTI Spindle Technology
At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

For many manufacturers, Kessler spindles are the heart of their business. We know because Kessler spindle repair is the heart of ours. That is why we have taken the time to master the skills and tools necessary to resolve any Kessler spindle problem quickly and efficiently. Our procedures for machine tool spindle failure analysis, spindle calibration, and spindle testing are part of what makes us one of the largest spindle repair specialists in the country. We strive to reduce your downtime and ensure your spindle runs better than it did when it was new.

Contact and Intake

At GTI we have live support staff taking customer calls 24 hours a day, 7 days a week. With our three state-of-the-art facilities in the U.S., you can save on shipping time and cost, and in some cases, we can perform the spindle repair at your location. We are diligent about tracking all new arrivals so you can stay on top of your spindle’s progress throughout the repair process.

Disassembly, Cleaning, & Inspection

As we disassemble the spindle, we search for signs of contamination, lack of lubrication, support equipment failure, misuse, or anything unusual. We clean all disassembled parts and conduct numerous tests to see how the Kessler spindle compares to industry specifications. We check the run-out, alignment, optimal tolerance levels for housing bores, as well as shaft journals and parallelism. We inspect the bearings for preload, contamination, overloading, fretting, overheating, and make a recommendation for replacing your bearings to extend spindle life and improve performance. We search for the origin of the failure, to fix it correctly, and to provide you with a detailed guide to prevent the issue in the future.

Machining, Grinding, & Balancing

If necessary, we can change worn out Kessler spindle components with custom built replacement components in our on-site machine shop. This allows us to get your part fixed faster without having to rely on the OEM, saving you valuable time and money. We also do our own in-house grinding and have a climate-controlled space, where we can grind to precision run outs with tolerances of 0.0001 or better. We use our state-of-the-art balancing technology, developed by GTI Predictive Technology, to 2 stage balance all spindles that we rebuild. We will component balance and then perform final trim balance at maximum RPM to achieve the lowest unbalance and vibration levels possible.

Reassembling & Testing

We put it all back together with new bearings, seals, O-rings, spacers, Belleville washers, and any other reworked components in our controlled assembly area to prevent contamination. Once reassembled, we run extensive tests covering runout, temperature, and vibration from 0 RPM to the maximum speed. We will then continue to test run at maximum RPM until we feel confident that your Kessler spindle is performing optimally—which is often better than when it was new. Final vibration tests will read at .0395 overall velocity and the displacement specs will meet the recommended ISO grade scale.

Final QC and Return

Every Kessler spindle that we rebuild is then put through a redundant final QC process by an independent technician to ensure that all of our rebuild processes and specifications have been achieved or exceeded. We paint and pack your newly repaired spindle in non-corrosive packing material and encase it in foam. It gets shipped to you in either a heavy-duty shipping box or a custom-built wooden crate to ensure a safe return to your facility. When you unpack your Kessler spindle, you’ll not only be pleased with how it looks, but you’ll be amazed at how well it performs.

About GTI Spindle Technology

At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

Breakdowns of any kind are a major roadblock for production efficiency. With machines out of operation, manufacturers find their revenue decreases as overhead costs skyrocket. While not all breakdowns are avoidable, some definitely are. Only 30% of machines live their full lifespan because of poor maintenance and upkeep. Knowing why spindles breakdown before their time is the best way to prevent an untimely end to your machines.

Contamination

One of the most common factors in premature spindle failures is poor air supply. Particulate contaminants and moisture especially are often disastrous. Maintenance personnel and machine operators often focus on lubrication to the detriment of all else, but a contaminated air supply is known as the silent killer of spindles. Around 80 percent of spindle failures are because of contamination. Many assume that contamination is exclusively caused by external sources such as grinding swarf or coolant, but in actuality, many spindle machine tool users are killing their own equipment. Ensuring a dry air supply is one of the best ways to protect your production line from contamination related breakdowns.

Overloading

It is always best to utilize the right type of spindle for the right job. The most common causes of overloading include improper feed rate, excessive preload, faulty belt tension, and poorly sized bearings. Doubling the speed of a spindle beyond the manufacturer’s recommended rating can reduce the lifespan of a spindle by half. It’s also essential to ensure that bearings have the proper amount of preload – the amount of force exerted against the rolling elements without external force. Too much preload will wear down the parts when not in use, and too little preload will prevent the tool from performing properly.

End of Spindle Life Failure 

Seemingly identical spindles operated under perfect conditions may not last the same amount of time. Manufacturers estimate the time period that 10% of bearings will fail under optimal usage conditions. This calculated timeframe is known as a machine’s basic life or L₁₀, and can be used to estimate how long you can expect a machine to last. Following a proper maintenance routine can help ensure you get the longest lifespan out of your equipment, but even under perfect conditions, breakdowns do occur. That is why it’s vital to have a trusted spindle repair technician to turn to when a breakdown does happen.

About GTI Spindle Technology

At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

Contrary to popular belief, the manufacturing industry in the United States is stronger than ever. In fact, it’s the strongest in the world and is responsible for nearly 20% of all the world’s goods. However, it is true that manufacturing has changed immensely in the past few decades and will continue to evolve in the future. Factors such as outsourcing, automation, and the leaps and bounds computer technology makes every year will drastically impact every facet of manufacturing. For those companies trying to keep up and maintain a competitive edge, it’s critical to understand how the evolution of the manufacturing landscape affects spindle repair.

Outsourcing Puts OEMs Farther from Their Products

With outsourcing on the rise, many industries make the bulk of their products internationally in places like Asia, Africa, and Mexico. While this greatly reduces the labor costs for the OEM, it also increases the distance between them and where their products will be in use. As anyone who works in manufacturing knows, downtime is the death of productivity. Every minute a plant is shut down is money lost. The shipping and logistics required for OEMs to repair many of their own products adds enormously to the downtime costs for their customers as machines stay out of operation. For this reason, many OEMs partner with independent repair specialists to provide closer support. Independent repair technicians can also provide onsite repairs for many common spindle problems to get the production line up and running even faster.

The Skilled Labor Shortage Makes Hiring Competitive

Currently, the manufacturing industry is experiencing a severe labor shortage. As equipment evolves and U.S. machinery becomes more complex, the need for skilled labor has skyrocketed. Many companies are turning to high schools and creating outreach programs to encourage the next generation to pursue careers in manufacturing. However, recruiting the right talent isn’t cheap. Some estimates place the cost of recruiting experienced, skilled labor at over 100% the annual salary cost. For this reason, it’s often inefficient for manufacturers to rely on in-house technicians for all their spindle repair needs. Independent companies specialize in recruiting and training the best candidates, and with their broad customer base, these technicians typically have a much greater depth of knowledge – handling all kinds of repairs every single day.

The Exponential Growth of Technology Makes Staying Ahead More Difficult

It’s long been said that computer technology makes significant advancements every 18-months, thanks to the technological exponential growth known as Moore’s Law. Recently, researchers at MIT found that Moore’s Law can be applied with similar accuracy to technological growth across many industries including manufacturing. With every new piece of equipment or accessory, there becomes a need to master a new skill set. In order to avoid falling behind, manufacturers rely on high-end independent repair companies to keep apprised of the latest advancements in their industry.

To learn how an independent spindle repair company can best serve your needs and keep your production line ahead during these changing times, contact the professionals at GTI Spindle Technology today!

About GTI Spindle Technology

At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.

American manufacturing has undergone significant transformations over the last few decades, but in recent years has made some of its most impactful changes yet. A result of technological innovation, recent strides can be attributed to the rise of automation, robotics, and machine-to-machine communication. Today, manufacturing and automation are synonymous, leaving many technicians questioning their relevancy on the production line. The reality: developments in robotics, additive manufacturing, IoT and other new technology all present increased demand for skilled workers.

Robotics

It’s undeniable that developments in robotics have revolutionized industrial automation and it’s only expected to continue growing in the coming years. Most think of the robots used on assembly lines in major automotive manufacturers, but in reality, robots range in size and purpose throughout the industry. From machines that load and unload vehicles to flip-stations that rotate parts for the next stage of assembly, regardless of how small a robot’s task, evidence shows that automation increases production, improves quality, reduces manufacturing waste, and creates a safer workplace for workers.

3D Printers

3D printing provides similar promise to improve output and decrease waste. These machines are capable of creating complex parts from the same ingredients which can be quickly and inexpensively reconverted into other items. 3D printers also provide greater flexibility because one machine has near unlimited versatility with the kinds of parts it can create, compared to the specialization of a traditional robotic assembly line.

The future of 3D printers is vast. Rows of 3D printers will manufacture numerous complex parts using additive manufacturing; the machines print the liquified building material such as plastic, ceramic, and metal, one layer at a time. As parts are completed, they can be moved into the assembly line where traditional robotic assemblers will construct the 3D printed parts into the final product.

IoT  

IoT systems have already improved efficiency between people and machines by automating the diagnostic and repair process. In addition, advances in software development and artificial intelligence are projected to drastically reduce downtime and wasted dollars in the coming years. As more manufacturers adopt IoT into their predictive maintenance systems, the cost of repairs will drop dramatically. By 2020, it’s expected that nearly $300 billion will be spent on IoT technologies, products, and services, with the majority of that money coming from the manufacturing sector.

New Technology, New Demand for Skilled Labor

History shows that advances in technology open doors for employees to new opportunities. For example, in the past decade, the need for skilled workers in metal forming, fabrication, service repair, and welding has increased. Studies show that by 2024, the U.S. will need an estimated 90,000 more welders alone. Where experts anticipate more and more collaborative relationships between man and machine as advancements continue, it becomes difficult to predict the number of jobs that haven’t been created yet. Every new machine or software brings with it the need for skilled workers to master the technology and keep it running efficiently.

With years of experience in high-tech spindle repair, GTI Spindle is perfectly suited to handle changes in the future of manufacturing. Contact us today to learn how your company can benefit from our years of experience and stay up-to-date on the latest in automotive, manufacturing, aerospace, and agriculture spindle repair services.

About GTI Spindle Technology

At GTI Spindle Technology, we specialize in high-quality spindle diagnosis and repair. Getting your business back into full operation and minimizing downtime is our mission. We offer in-house, on-site, and emergency assistance for machine tool spindle failure analysis, spindle repair, and complete spindle testing. With an extensive range and expertise in a diverse group of industries, our customers know that they are getting the highest quality of spindle repair and customer service. Click here to find out more.