Resolving there are problems, resolve to find the solutions

Plant Engineering does a series of Roundtable discussions each year designed to get at the crucial issues facing manufacturing in general and plant-floor management in particular. In this issue, you'll read excerpts from the discussions we had at the Plant Engineering Manufacturing Summit in Chicago.


Plant Engineering does a series of Roundtable discussions each year designed to get at the crucial issues facing manufacturing in general and plant-floor management in particular. In this issue, you'll read excerpts from the discussions we had at the Plant Engineering Manufacturing Summit in Chicago. The full transcripts will be at . There's a lot of great information in there.

These are great discussions because rather than working off a PowerPoint presentation, the speakers are engaged with each other and with the audience to work through crucial issues.

One of the best Roundtables I've been involved with this year was an informal discussion over a barbecue dinner in Houston, at the Plant Success event. I blogged a good bit about this event on this past month. There were no slides, no charts and no graphs. Just good barbecue and a group of manufacturing leaders facing the same problems.

While there is genuine concern about job outsourcing, there is a far greater concern about losing skilled workers in the coming five years with no obvious way to replace them. There was a sense that jobs going overseas are fueling growth overseas, and that U.S. expansion by several major international manufacturers (Hyundai, Toyota, Kia) is an indication that domestic manufacturing is alive and showing healthy signs.

And as I noted at one point in the conversation, Apple announced recently that it had sold 100 million IPods globally %%MDASSML%% an indication that if the U.S. develops the right product, the world will pay attention.

I'm not sure manufacturing's problems were solved that night, but the key issues were put on the table and the speakers were all engaged in finding solutions. We resolved that there were serious questions, but there was also resolve to find the answers.

Manufacturers talked about setting up paid high school internships and intensifying college recruiting to bring new, fresh ideas into manufacturing. They see that while China and India continue to develop their manufacturing bases, they're also developing a middle class that will want manufactured products. That leads to two big questions: can Asia supply the world and its own citizens, and at what point will costs and wages and the basic laws of economics pull the manufactured costs of goods in line with the Western world?

There is a change afoot in manufacturing, and so far it's been change fraught with pain. The people I talked to in Houston, however, sounded committed to playing through the pain. More than just survival, though, there is a sense out there that manufacturers are looking past the big picture to see what they can do on their own home turf.

And they keep talking to other manufacturers. It's through those discussions that we can find common ground and common solutions.

The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
Doubling down on digital manufacturing; Data driving predictive maintenance; Electric motors and generators; Rewarding operational improvement
2017 Lubrication Guide; Software tools; Microgrids and energy strategies; Use robots effectively
Prescriptive maintenance; Hannover Messe 2017 recap; Reduce welding errors
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Research team developing Tesla coil designs; Implementing wireless process sensing
Commissioning electrical systems; Designing emergency and standby generator systems; Paralleling switchgear generator systems
Natural gas engines; New applications for fuel cells; Large engines become more efficient; Extending boiler life

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
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This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
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This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
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