2Meeting GoalsCreate a Greater Awareness of the Opportunities in Advanced ManufacturingIdentify Regional Curriculums in Education that Interface with Advanced Manufacturing TechnologyExplore Career Pathways that Contribute to the Needs of Regional ManufacturersIdentify Critical Next Steps
3Education and Manufacturing, Where & How do they Connect for Success?
4There are only three ways that a country builds wealth – you; Make thingsMine things and;Grow thingsEverything else is ancillary to that. Manufacturing has the best record for add-on jobs. For every job that is created in manufacturing, there are multiple add-on jobs that are created as a result.” –Pat Lee, Fabricators & Manufacturers Association
5Not only the wealth; but the independence and security of a Country, appear to be materially connected with the prosperity of manufactures.~ Alexander Hamilton (1791)
6Is Manufacturing a Good Career Path Option? Manufacturing in America is Big Business with Unlimited Potential for Current and Emerging GenerationsManufacturing Creates Economic WealthThe United States Must be Competitive in Manufacturing to Survive Today’s Global Business Environment / EconomyManufacturing Can’t Just Survive; It Must ThriveCooperative Efforts are Vital at All Levels (Business & Industry, Education and Community)Manufacturing Organizations Will Need Thousands of Qualified People to Replace Retiring Workers and / or Openings. Note:Approximately % of the manufacturing workforce is on the shop floor (semi-skilled operators / assemblers etc)Replacements – High Demand / Short SupplyTechnology is Vastly Changing the Manufacturing EnvironmentMore Professional Jobs Will be Intergal to the Success of ManufacturingManufacturing Jobs Will Continue to Pay More Per Year Than the Average Service JobManufacturing Companies are Posturing to Bring Manufacturing Back to the United States
7State of Manufacturing Manufacturing today is not dead; it’s just differentNew machineries and materialsIncreased automation and smarter logistics define modern manufacturing.Long Term Critical Need for an Educated Skilled Work ForceGlobalizationTechnology / InnovationNew Types of ProductsDifferent Infrastructures
8In the most recent data, manufacturers contributed $2 In the most recent data, manufacturers contributed $2.09 trillion to the economy, having risen steadily since being $1.73 trillion in 2009.The sector currently accounts for 12.0 percent of GDP. For every $1.00 spent in manufacturing, another $1.37 is added to the economy, the highest multiplier effect of any economic sector. The US produces 21% of all global manufactured products.Manufacturers can choose from locations in an increasing number of communities with location advantages that meet their needs. Excellence in education is a key factor in site selection.Manufacturing supports an estimated 17.6 million jobs in the United States about one in six private-sector jobs. More than 12 million Americans (or 9 percent of the workforce) are employed directly in manufacturing.In 2013, the average manufacturing worker in the United States earned $77,506 annually, including pay and benefits. The average worker in all industries earned $62,546. Taken alone, US manufactures would be the 8th largest economy in the world.Manufacturers in the United States are the most productive in the world, far surpassing the worker productivity of any other major manufacturing economy, leading to higher wages and living standards.
9InnovationInnovation is the key driver of competitiveness, wage and job growth, and long term economic growth. The U.S. is lagging behind in innovation in its manufacturing sector relative to high-wage nations such as Germany and Japan.Individual companies cannot justify the investment required to fully develop many important new technologies or to create the full infrastructure to support advanced manufacturing. Private investment must be complemented by public investment (public-private partnership).A sustainable, lean, industry-focused innovation model will create an environment for American manufacturing innovation that will advance U.S. manufacturing competitiveness and drive export growth.
11Priorities to Improve Manufacturing Competitiveness ChallengesOpportunitiesPercentage of votes for an option
12Manufacturers Recognize the Importance of Innovation to Competitiveness How important will having world-class manufacturing technologies be to your company's overall competitiveness in the next 5 years?Extremely importantPercentage of respondents selecting an optionNot at all importantSource: 2011 EWI Member Survey; 350 respondents
13Insufficient Emphasis on Maturing New Manufacturing Technology US Innovation Gap:Insufficient Emphasis on Maturing New Manufacturing TechnologyStructural problem requires a structural solutionBasic Research/EducationUniversities,NSF Centers,Federal LabsHigh-risk researchLong time horizonNot focused on shop floor implementationManufacturing Technology InnovationTechnical InnovationMissing MiddleManufacturing technology innovation, maturation, commercialization, insertionMedium time horizonHigh impactBest PracticesIndustry,NIST MEPIncremental improvementOff the shelf technologyShort time horizonTime to deployment
14An Effective Model Must Overcome Four Principle Barriers What are the biggest barriers to successful collaborative manufacturing technology development?1. Funding2. IP ownership3. Competition4. DeliveryPercentage of respondents selecting optionSource: Aug EWI member survey; 550 respondents
15Successful innovation is the use of new technological knowledge, market knowledge, and business models that can deliver a new product or service, or product/service combinations, to customers who will purchase at prices that will provide profits.The majority of workers are in frontline positions, yet most organizations do not align their training and educational Pathways to effectively support their largest group of employees.Statistics and common sense tell us that the vast majority of workers are engaged in frontline positionsDespite their overwhelming numbers, we don’t read much about frontline workers. Their indisputable impact on corporate bottom lines notwithstanding, we don’t see many business books written about how to help frontline employees or leaders be successfulThere is an untouched innovation factory residing in the collective brain trust—customer insights, product ideas, and service upgrades—that most companies have no idea how to access.BloomBurg Business Week 2012
167 Success Factors to Innovation Utilize new technology and market knowledge, to create business models that can deliver a new product or service, or product/service combinations, to customers who will purchase at prices that will provide profitsFoster a culture that embraces risk takingCreate a unique alignment of mission & goalsAccept a climate where mistakes are o.k.Emphasize exploratory thinking, idea generation, and experimentationDevelop interpersonal relationships & teamwork that are cohesive and supportiveFully engage in cross-functional collaboration, communication and execution
17Manufacturing Pipeline Example from US Chamber of Commerce
182 Components of the Manufacturing Accelerator Network Industry ConsortiaApplication CentersSector specific; organized around industry clustersMember based collaborations; financial support to demonstrate relevanceGovernment/industry cost share pre-competitive technology developmentEngages universities and national labs to address “grand challenges”Workforce development through educational institutionsIP framework that reduces barriers to collaborationManufacturing technology specific; capabilities that are world-beatingFacilities and expertise to support all sectors and business sizes501(c)(3) not-for-profit corporations focused on industry clientsPrimarily industry funded to implement technology for proprietary applicationsModest government funding to build core capabilitiesIP framework that reduces barriers to implementation
19Bridging the Innovation Gap Universities,NSF Centers,Federal LabsHigh-risk researchLong time horizonNot focused on shop floor implementationIndustry ConsortiaPrecompetitive technology developmentWorkforce TrainingTechnical InnovationApplication CentersMature and commercialize technologyImplement for industrial applicationsNational network of industry-focused application centers and consortia linked to existing assetsIndustry,NIST MEPIncremental improvementOff the shelf technologyShort time horizonTime to deployment
20Typical Manufacturing Plant Structure MaterialPurchasedManufacturedBuildingInfrastructure, Machines, Equipment & SuppliesPeople80 – 85 % Direct15 – 20 % IndirectLeadershipSmart, Innovative and AgileLearningTribal Knowledge + Formal EducationWork TeamsEmpoweredEngaged, and EfficientSatisfied CustomersRepeat BusinessNew Business
21An Existing Innovation Opportunity The majority of workers are in frontline positions, yet most organizations do not align their training to largest group of employees.Statistics and common sense tell us that the vast majority of workers are engaged in frontline positionsDespite their overwhelming numbers, we don’t read much about frontline workers. Their indisputable impact on corporate bottom lines notwithstanding, we don’t see many business books written about how to help frontline employees or leaders be successfulThere is an untouched innovation factory residing in the collective brain trust—customer insights, product ideas, and service upgrades—that most companies have no idea how to access.
23Problem SolvingLike all organizations, manufacturing companies have problems to solveTo resolve a problem a team of motivated cross-functional members are selected from the following areas;ManufacturingQualityMaintenanceEngineeringShipping/ReceivingAccountingPurchasingSalesEtc……
24Example of How a Problem is Defined: Problem SolvingExample of How a Problem is Defined:
25Problem SolvingExamples of tools utilized for data collection to either search for a problemor verify a countermeasure:
26Measuring DevicesAs manufacturing has evolved, inspection is no longer conducted by Quality Control.To be more competitive, indirect labor reductions require that these tasks be performed by manufacturing operators.Key measuring devices utilized by manufacturing are Calipers and Micrometers.
27Measuring DevicesThe main use of the Vernier caliper is to measure the internal and the external diameters of an object.
28Measuring DevicesMicrometers are used for precise measurement of components in manufacturing, machining, and mechanical engineering.Types of Micrometers
29Blueprint ReadingBasic blueprint reading is needed in the manufacturing industry to enable team members to understand how to:Identify the height, width, and length dimensions of a part by reviewing a drawing.Interpret the various symbols and notations used on drawings (Geometric Tolerancing).It is necessary for team members to convert Metric to English and English to Metric as drawing callouts vary.
30Blueprint Reading Common Geometric Tolerancing callouts: Example of common manufacturing Blueprint:
31Work InstructionsIt is critical for manufacturing team members to understand and follow work instructions.A work instruction is written after a proven method of producing a quality product in a safe manner has been determined.Performing work the same way every time may be referred to as Standardized Work.Quality products can be produced time after time when a good method is created and standardized work is followed.Any out-of-standard work destroys continuous flow and makes it difficult to maintain efficient and consistent production.
34SummaryFacts:Manufacturing in America is Exciting with Unlimited Potential for Current and Emerging GenerationsManufacturing Creates Economic WealthThe United States Must be Competitive in Manufacturing to Survive Today’s Global Business Environment / EconomyManufacturing Can’t Just Survive; It Must ThriveCooperative Efforts are Vital at All Levels (Business & Industry, Education and Community)Opportunities:Manufacturing Organizations Will Need Thousands of Qualified People to Replace Retiring Workers and / or Openings.Technology is Vastly Changing the Manufacturing EnvironmentMore Professional Jobs Will be Intergal to the Success of ManufacturingManufacturing Jobs Will Continue to Pay More Per Year Than the Average Service JobManufacturing Companies are Posturing to Bring Manufacturing Back to the United StatesConcerns:A Negative Image is the Single Biggest Problem of ManufacturingParents and Educators do not View Working in a Factory as an Acceptable CareerTo Generate Economic Growth / Development, Communities Work Hard to Recruit New Business / Manufacturing; but Have Done Very Little to Promote Manufacturing EducationThere is a Strong Resistance to Change At all LevelsThe Clock is Ticking
35Advanced Manufacturing Technology Training Program A partnership between Henderson County Schools, Decatur County Schools and the Tennessee College of Applied Technology – Jackson
37Manufacturing in Tennessee According to the Tennessee Manufacturers Register:Tennessee is experiencing a “manufacturing renaissance” due to improvements in the national economy, the state’s business friendly environment, educated workforce and ideal location for shipment of goods.From September 2012 to September 2013, Tennessee added 4,197 manufacturing jobs.We now have 6,990 manufacturers employing 385,858 workers across the state.Source: The Tennessean, “TN Manufacturing Jobs up by 4,197, beating National Average Gains”. By: C. Chambers Williams, III, December 13,
38Advanced Manufacturing in LWIA’s 11 & 12 LWIAs 11 & 12 encompass all of West Tennessee except for Shelby County.*Through 2016, there will be 1,050 annual openings in “direct labor” jobs and 925 annual openings in “indirect labor” jobs.“Direct” vs. “Indirect” laborAdvanced Manufacturing Career Pathway *Source: TN Department of Labor and Workforce Development, LWIA 11 and LWIA 12 Employer Survey
40Advanced Manufacturing Technology (AMT) Program Industry has expressed a need for better-trained, entry-level “Direct” laborThis program is designed to meet the needs of local manufacturing facilities by providing a pool of well- trained, entry-level production associates.Graduates will complete both lecture and hands-on instructional activities (classroom and lab) that equip them with an understanding of modern manufacturing processes and procedures.
41Advanced Manufacturing Technology (AMT) Program TCAT Jackson will deliver the training via a “dual- enrollment” arrangement with the local school systems.Students will receive both high school and TCAT credit for passing the courses.In Henderson County, Lexington High and Scotts Hill High School students will come to the TCAT extension campus for the program.The Manufacturing Skills Standards Council’s (MSSC) Certified Production Technician™ (CPT) computer- based course work is integrated into the program.
42Advanced Manufacturing Technology (AMT) Program The Certified Production Technician™ (CPT) program covers five (5) areas of emphasis via a computer-based learning system:Industrial Safety, Quality Practices & Measurement, Manufacturing Processes & Production, Maintenance Awareness and Green Production.When a student passes the required exams, they earn the CPT credential.
43Advanced Manufacturing Technology (AMT) Program Win/Win/Win:Meets local industry needsIntroduces students to manufacturing careersEquips students with a nationally recognized credential that validates their skillsGives students another option to keep them engaged in school and keep tracking to graduationContributes to local ECD efforts (industry recruiting)Students earn post-secondary credit at the high school level (paid for by lottery funds)
44Advanced Manufacturing Technology (AMT) Program Challenges:Gaining “buy-in” from more local industryPreferential hiring?Taking advantage of outside funding opportunitiesTCATs just had a 4.6% reduction in state appropriations“Drive to 55” (LEAP)Cost $750 to credential each studentGenerating student interest
45In order to revitalize manufacturing and give a dynamic boost to our economy, we need to restructure the way we are educating our students and employees.
46Blended Learning Pathway for Manufacturing Certification https://www.youtube.com/watch?v=gG1pw6A-Usw
48Innovative Pathways for Student Success Delivery Options Integrate CPT Modules into existing CTE Courses with Possible Options for Dual EnrollmentBlended Learning Options during the School Day for non-CTE StudentsVirtual Deliver Outside the Regular School Day with Post Secondary InstitutionsSummer Academies that Lead to a Fast Track Credentialing Options to Access Tennessee Promise FundingMore Options Are Possible
51For Education, Manufacturing and Business to Continue to Survive and Thrive In the Future, Strong Passionate Leadership is Required. We must have: Leaders who will together cohesively and who will: Encourage, Lead and Manage Change Actively Participate in Pursuing and Procuring Funding Dedicate The Time it Takes to Succeed Make a Long-Term Commitment Execute Courageously Be dedicated to Continuous Improvement Lead By Example Develop a New Way of Thinking Regarding Innovation and Agility Think “Out of the Box” and; Formulate, Communicate and Facilitate a “New Work Together Paradigm”
52Needed: Tactical and Strategic Leaders Who Are: 1) Innovative ~ Predict the Future by Creating it2) Agile ~ Ability to Move Quickly and Easily3) Engaged ~ Positive Emotional Attachment4) Execution (ers) ~ Discipline to Get Things Done
53Quotes to Consider“Let us put our minds together and see what life we can make for our children” ~ Sitting Bull“The true meaning of life is to plant trees, under whose shade you do not expect to sit” ~ Nelson Henderson