Recent world events and fluctuations in supply chains have shed light on the importance of manufacturing production in North America. This enlightenment is fueling a growing trend towards reshoring operations at home, therefore avoiding inconsistencies related to offshore channels. Abroad, negative variables include the rise in factory wages, import regulations, and the risk of intellectual property theft. At home, advantages include more favorable tax burdens, new and cheaper automation tools, better quality control, and quicker product-to-market cycles—to name a few. Together, these forces have the potential to strengthen the Made-in-America label.
Four decades in, PBC Linear has remained a pillar of Midwest manufacturing in linear motion. We continue to solidify our home court advantage as one of the largest privately-held linear motion manufacturers in the United States. That said, we are not just local! Our customer reach includes the shipment of products to over one hundred countries. As we celebrate our 40th Anniversary, we recognize the competitive need to consistently devote investment dollars to hardware, software, and personnel. These include cobot technology, machine monitoring systems, workforce upskilling, and our new expansive flexible manufacturing system (FMS). In fact, these recent and substantive investments reflect the ambitious goal to double the size of the company over the next five years.
As PBC Linear continues to grow, we are evolving from a standard product manufacturing company into a technology OEM company. In essence, PBC Linear has three different business models. First is the conventional model that consists of standard catalog products that are often ready to ship. The second model consists of similar types of products that have only slight modifications. For example, a standard product like Redi-Rail might have different lengths, and therefore defined by a smart part number.
Lastly, there are the “true” engineered-to-order products. Here, PBC Linear takes one of their core competencies and modifies the shape to fit a specific customer application. In these situations, our team of engineers are often integral in helping customers find the best solutions that are consistent with the needs of OEM designs.
Above: Examples of custom engineered-to-order products. This is one way that PBC Linear offers a value-added approach to finding the best linear motion solution.
PBC Linear continually assesses and updates its factory equipment based on business and production needs. Over the last 5 years, PBC Linear has invested nearly $20 million in capital equipment from industry-leading machine tool companies across the globe.
Cobot Feeder — One big push has been the implementation of new automation tools such as cobots and our own proprietary Cobot Feeders. Designed by our research and development team under the Applied Cobotics brand, Cobot Feeders are designed to assist the cobot and substantially boost robot productivity. See more on how our customers and our own shop are benefitting from Cobot Feeder technology.
"We built the Cobot Feeder for ourselves first, and now we’re commercializing it.” – David Dieter, President
Cobot Feeder loading/unloading parts trays in position for the cobot.
FMS — Our largest capital expenditure this year focuses on the impressive Flexible Manufacturing System (FMS), acquired from MCM (Machining Centers Manufacturing). At over $5 million, this state-of-the-art machining center replaces the current system, supporting our automated milling and turning functions. This upgrade represents a 20-year asset for PBC Linear and its customers through increased production capacity, ensuring high quality parts and on-time delivery.
The FMS features four horizontal CNC mills, a 90-pallet change system, and an extensive tool manager that can support over 1,500 tools. These assets, along with a modular system, have allowed PBC Linear to customize and install their FMS layout in a series of five stages. As the company continues to grow and evolve, the flexibility of the FMS design will provide the option of additional pallet storage and CNC machining stations, and a Coordinate Measuring Machine (CMM) for detailed inspection reports.
Before installation of the FMS could begin, a new foundation needed to be prepared. An 18,000 square foot space within the factory was cleared, excavated, and repoured to create a suitable foundation to accommodate the new system.
“We’re looking at the FMS as a 20-year investment for PBC Linear.” – Tom Schroeder, Executive Vice President
The FMS installs in five stages over an 8-month span, with full completion by the end of March 2023. Stage one comprises the first Clock 1200 EVO 4-axis machining center, mirrored tool storage with 398-tool capacity, loading and unloading stations, and more. Stage two includes the addition of another Clock 1200 EVO 4-Axis Machining Center, and so on. Once completed, PBC Linear will have an upgraded machining center with maximum rigidity and accuracy.
Tool management is an essential component of the FMS system. The CLOCK EVO tool-magazine features a tool-sharing function that provides assets to each machine depending on their production scenarios. This creates flexibility and efficiency along the entire FMS production schedule.
The ongoing investment into machine upgrades, Cobots and Feeder technology, and the FMS will ensure continued efficiency throughout the production cycle. For our customers, that means a commitment to keep costs and lead times low, while offering a high level of quality.
Modular components of the FMS are moved into position.
Loading and tooling stations for the new FMS installation.
Investments at PBC Linear don’t end with hardware improvements. Assets in machine monitoring technology play a vital role as well, acting like a data-point liaison between personnel and machinery, and ultimately benefiting customers. One example is the newly implemented Amper machine monitoring system.
Amper is a factory operating system that uses digital tools to track, diagnose, and improve factory operations. Non-invasive sensors are connected to machine power supplies which then channel data through dashboard software, allowing real-time visibility into the shop floor. Operations managers can accurately assess each part throughout the manufacturing process.
Amper provides metrics to help managers pinpoint problems with their machinery and improve their Overall Equipment Effectiveness (OEE). This real-time data is essential for improving processes, removing human error, and ensuring that measurements are as accurate as possible. PBC Linear officers can then build out a plan for future resources and upgrades that help satisfy customer needs.
See more on how PBC Linear is using Amper by reading the blog: Building a Foundation for Growth with Machine Monitoring.
None of these investments are truly effective without the right people in the right places. As we continue to push the automation envelope, machine operators, young and old, will need to be trained in higher level roles such as multiple machine management and cobot functions.
To upskill these essential positions, PBC Linear has been using a new kind of software training that involves augmented reality software and 3D glasses. The software and glasses work together to project holograms onto the clear panel at the front of the glasses, and create interactive instructions within the viewers field of view and corresponding environment. This tool not only provides PBC Linear with a more consistent training program, but also documents and captures industry knowledge that may otherwise be lost to retirement and other factors.
See more on how PBC Linear is using AR training methods by reading the blog: Advanced Manufacturing: Augmented Reality Training.
The benefits of these investments land far outside of the company’s bottom line. According to the Commerce Department, a dollar of final demand for manufacturing generates $1.33 in output from other sectors of the economy. This multiplier effect is often higher than the multiplier from information sectors and fields such as retail trade and business services.
For the Rockford area, PBC Linear is part of a larger network that helps to attract and retain valuable talent. As we sail into the uncharted waters of the current economy, one mantra remains the same: Manufacturing is important to the overall health of our economy, and will continue to play a vital role in regional economic health as well.
Stay tuned for more information coming on our
This event will take place later this year (2023), and include food, beverages, and tours focused on investments in automation, innovation, and the people that make PBC Linear successful.
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