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Posts Tagged ‘manufacturing’

Photo: John Ydstie/NPR
Apprentice industrial clerk Henrik Tillmann assembles a valve for a commercial aircraft galley kitchen at Hebmuller Aerospace near Dusseldorf, Germany.

The old-time way of learning a trade — by working as a low-fee apprentice for a few years — never completely died out and remains the reason Germany is a manufacturing powerhouse.

In the second of three reports at National Public Radio (NPR), John Ydstie explains.

“Manufacturing accounts for nearly a quarter of Germany’s economy. In the U.S., it’s about half that. A key element of that success is Germany’s apprenticeship training program.

“Every year, about half a million young Germans enter the workforce through these programs. They provide a steady stream of highly qualified industrial workers that helps Germany maintain a reputation for producing top-quality products.

“Henrik Tillmann is among the current crop of young apprentices. The 19-year-old is training at Hebmuller Aerospace to be an industrial clerk, which qualifies him to do a variety of jobs from materials purchasing to marketing. Each week he spends three-and-a-half days at the company’s production center, and a day and a half at a government-funded school. Before he can become a clerk, though, Tillmann must first learn how to build the valves Hebmuller sells to aerospace companies.

“He will be a better clerk, says his boss, Axel Hebmuller, because he’ll know the valves inside out when he describes them for customers. …

“Hebmuller says only 3 of the 16 people who work for his company went to university. …

“Felix Rauner, a professor at the University of Bremen, says … the U.S. approach to vocational education has been ineffective partly because it’s often not directly connected to specific jobs at real companies.

“Also, says Rauner, U.S. society has stigmatized vocational education, so most American parents see college as the only path to status and a good career for their children. Rauner says there’s a troubling trend in that direction in Germany, too. But, in Germany there’s still lots of prestige attached when someone, trained through apprenticeship, achieves master status.”

In the US, entrepreneur and philanthropist Gerald Chertavian had to pretty much reinvent the wheel for his nonprofit Year Up, building partnerships with companies to give his organization’s young adults serious internships. The internships are not quite apprenticeships but they lead to real skills and real jobs. Year Up’s expansion around the nation is proof of the pudding.

I’m also familiar with a genuine US apprenticeship effort in Rhode Island. Led by Andrew Cortés, founder of Building Futures and Apprenticeship Rhode Island, it produces the skilled construction workers that employers look for.

For more on Germany’s approach, click here.

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You haven’t heard the last word on tiny houses from this blog yet. Just check out Treehugger reporter Kimberley Mok’s amazing story about using a 3D printer to create a tiny house and SUV that can create, store, and share energy. Unreal but true.

“Designers from architecture firm SOM, University of Tennessee and researchers from the US Department of Energy’s Oak Ridge National Laboratory are cleverly tackling the energy issue by using a concept they call ‘integrated energy.’

“Their innovative design features a 3D printed house, that comes with a 3D printed SUV, which each generate, store and share energy — boosting energy efficiency both ways, while benefiting from the reduced construction waste and quick turnaround that comes with additive manufacturing techniques. …

“The design of both home and car uses carbon-fiber-reinforced ABS plastic (admittedly not the greenest of materials). The home was printed in separate modules that are assembled together and reinforced with steel rods, and insulated with a modified, highly efficient atmosphere insulation panels, resulting in a surprisingly strong and insulated structure.

“Certainly the most intriguing thing about the design is the reciprocal energy relationship that the car has with the house. … The 3D printed SUV is a hybrid that uses both electricity and natural gas to power itself. It’s parked on an inductive charging pad that allows it to send or receive energy from the solar-powered house — thus significantly solving the electricity issue on cloudy days. If there’s no electricity at all from either solar panels or car, the house can still tap into the energy grid. …

“Thanks to the additive manufacturing process, the prototype took only one year to realize from start to finish.” Read more here.

Photo: ORNL (Oak Ridge National Laboratory)

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Photo: The Slater Mill, Pawtucket, Rhode Island, bears the name of Samuel Slater, the father of the American Industrial Revolution.

Suzanne is interested in textiles as well as jewelry. (Check out the little purses she had made for Luna & Stella using weavers in Bhutan, here.) So I wasn’t surprised when she passed along an article from the NY Times on the U.S. textile industry today.

It seems that in addition to artists who create textiles for artistic purposes (see yesterday’s post), niche textile businesses still exist in the United States.

Rivka Galchen writes, “In 1776, America didn’t have a single textile mill. There were no spinning mules, no water-powered looms. There were only rumors of what such things might look like … Nearly every American woman, except the wealthiest, knew how to spin her own yarn and weave her own cloth …

“Samuel Slater was 14 when he began working at a cotton-spinning mill in Derbyshire, England. Seven years later, in 1789, he disguised himself as a farmer to pass English customs and board a ship to the United States. When he arrived in America, he got a mechanized loom up and running, then a textile factory and later factory towns, eventually becoming known as both Slater the Traitor and the father of the American Industrial Revolution.”

In 2010, Galchen continues, photographer Christopher Payne “came across a yarn mill in Maine and was transfixed by the way it seemed to exist both in the past and the present; it became the first textile mill he photographed.” He has since photographed more than 20.

“Langhorne Carpet Company, in Penndel, Pa., used to share its building with a hosier, but that business closed long ago. … On the day I visited, a young man in a hooded sweatshirt and jeans was making a five-color runner on one of the narrow looms, while an older man in a denim smock was restringing a broad one; 5,040 spools of yarn needed to be knotted on.

“ ‘We’ve stayed in business because we’ll take a 20-yard order, that’s our niche,’ said Langhorne’s president, Bill Morrow, whose grandfather and great-grandfather founded the company in 1930. … Langhorne has made reproductions of historic carpets for the Frederick Douglass house in Washington; the Congress Hall of Philadelphia; and the Rutherford B. Hayes home in Fremont, Ohio. …

“Langhorne employs about 40 people, whom it trains in-house. When a machine needs a new part, it is specially forged. ‘We’ve bought a lot of [our] machinery from other companies that have closed down,’ Morrow said.” More here.

Kind of nice to know that not all manufacturing has gone overseas. American ingenuity still can create jobs doing specialty work, training people in-house.

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The concrete that the ancient Romans created is so durable that it may hold lessons for those who want to reduce carbon emissions.

Paul Preuss, from the Lawrence Berkeley National Laboratory, explains.

“The chemical secrets of a concrete Roman breakwater that has spent the last 2,000 years submerged in the Mediterranean Sea have been uncovered by an international team of researchers led by Paulo Monteiro of the U.S. Department of Energy’s Lawrence Berkeley National Laboratory (Berkeley Lab), a professor of civil and environmental engineering at the University of California, Berkeley.

“Analysis of samples provided by team member Marie Jackson pinpointed why the best Roman concrete was superior to most modern concrete in durability, why its manufacture was less environmentally damaging – and how these improvements could be adopted in the modern world.

“ ‘It’s not that modern concrete isn’t good – it’s so good we use 19 billion tons of it a year,’ says Monteiro. ‘The problem is that manufacturing Portland cement accounts for seven percent of the carbon dioxide that industry puts into the air.’ …

“The Romans made concrete by mixing lime and volcanic rock. For underwater structures, lime and volcanic ash were mixed to form mortar, and this mortar and volcanic tuff were packed into wooden forms. The seawater instantly triggered a hot chemical reaction. The lime was hydrated – incorporating water molecules into its structure – and reacted with the ash to cement the whole mixture together.”

Apparently the key ingredients are found all over the world, enough to make a big difference in construction — and carbon emissions.

There’s more at the Berkeley Lab site for readers who can follow a technical explanation.

Photo: Berkeley Lab

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From a NY Times article by Stephanie Strom June 12:

“A few companies have taken some small steps to bring lost manufacturing jobs back to American soil, driven sometimes by declining labor costs in the United States, other times by dissatisfaction with the quality of goods made abroad.

“General Electric, for example, has created almost 800 jobs by building plants in Schenectady, N.Y., and Louisville, Ky., to make sophisticated batteries, some of which were previously made in China. NCR is making automated teller machines in Georgia that had also been made overseas. Last month, Starbucks announced it would build a factory in Augusta, Ga., that would employ 140 people and make the company’s Via instant coffee and the ingredients for its popular Frappuccino drinks. About half of Starbucks’s new employment overall will come in the United States, the rest internationally. …

“The effort is not all altruistic. Chinese labor has become more expensive, and Starbucks and other companies are looking at their supply chains more holistically. American Mug can deliver to Starbucks in four days, while Chinese suppliers may take three months.

“A Chinese supplier is also likely to require an order in the hundreds of thousands, increasing the risk that Starbucks will get stuck with inventory. And then there is the difference in shipping costs. ‘No doubt the cost of doing what we’re doing in East Liverpool [Ohio] at least in the initial stage will be more expensive for Starbucks, but the investment we’re making in this is about the conscience of our company and recognition that success has to be shared,’ [Starbucks CEO Howard] Schultz said.” Read more here.

We will probably never have the massive manufacturing we once had, but do send me what you hear about manufacturing picking up, even a little. For example, I recently heard about a new company in Massachusetts, 1366 Technologies, which makes silicon wafers for solar applications and has a manufacturing pilot going in Bedford. I mentioned this to a colleague who added that he knew of a new gin distillery in South Boston, which wasn’t really what I meant by manufacturing, but whatever floats your boat.

Photograph: http://www.1366tech.com/

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