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Center for Industrial Research and Service VOLUME 56 | Number 2 Collaborating to Predict Machine Failure A Davenport manufacturer of electrical safety devices is prototyping a new product intended to help equipment operators predict when their machines will fail. The new system, which is expected to rotary machines and detect vibration an assistant professor in Iowa State’s be released within the next year, will use changes in bearings. Grace is one of Department of Mechanical Engineering. special sensors created by Davenport- many companies seeking to translate Hu also oversees the System Reliability based Grace Technologies integrated with that technology to a broader market. and Safety Laboratory, which supports predictive algorithms using an Internet of several undergraduate and graduate “In the past, it used to be that a huge Things (IoT) architecture. The technology students conducting industry and generator at a utility company or a has grown out of a collaborative, CIRAS- academic research. turbine at a nuclear power plant would supported research effort between Grace use this, and maybe the system would An initial project in 2019 was funded and Iowa State University. cost $250,000,” he said. “The difference jointly by Grace Technologies and the Grace Technologies has estimated that is that we have systems that would be CIRAS Technology Assistance Program its new system could be worth up to $10 able to be placed on motors of all sizes (TAP). This was followed by two million to the company over a five-year and would cost a few hundred dollars.” research projects funded by the Iowa period as equipment operators rush to Board of Regents’ Regents Innovation The Grace-Iowa State relationship began save money on downtime, expensive Fund and a two-year grant from the in 2018 when CIRAS project manager repairs, and maintenance-related injuries. National Science Foundation (NSF). In Carey Novak followed up on an unrelated December, the NSF also recommended Drew Allen, Grace Technologies vice capstone project involving Iowa State $256,000 for the research as part of president for strategic innovation, engineering students. Novak initiated the government’s Small Business said large organizations in high-value deeper discussions about mutual Technology Transfer program. industries have long had predictive interests in research and development, maintenance capabilities because they especially predictive maintenance and Hu said Grace-related research use expensive equipment to monitor IoT, and connected Grace with Chao Hu, involves using machine learning to Continued on page 2 1
INSIDE THIS ISSUE Predicting Machine Failure continued from page 1 1 Collaborating to Predict create algorithms that can interpret are looking for a way to reliably predict Machine Failure bearing vibration data and predict that a machine is going to fail within a when machines are close to failure. certain window—a warning that arrives 3 CIRAS Helps Latham Hi-Tech Seeds Companies will be able to monitor the early enough to schedule maintenance Have Smooth Spring health of bearings and rotors in different but not so early that valuable machine life 4 CIRAS Guides Grinding types of machines and (because of must be sacrificed. Improvement at Weiler the IoT framework) do so with many “If you know that a piece of equipment machines simultaneously. 5 Online Orders Are an Elixir Following is going to fail in the next minute, that’s COVID-19 Collapse “This should help equipment manufactur- useless,” Novak said. “If you know that a ers plan their equipment maintenance piece of equipment is going to fail within 6 CIRAS Supplier Scouting Helps Bring and avoid unplanned downtime,” Hu said. the next 12 months but you don’t know Business to Iowa “That could be of huge value to them. If a when, then that’s useless as well.” 7 CIRAS Serves Iowa: By the Numbers bearing breaks on a piece of equipment Allen praised his company’s partnership and there’s no early warning, it’s not only 11 COVID-19 Assessment Helps Larson with CIRAS and Iowa State as a valuable the bearing that fails. The shaft and other Ensure Best Practices during Pandemic way of helping small companies explore components around it can get destroyed, the impact of a new idea. Without Iowa 11 Upcoming Events too. It’s a cascading effect.” State’s research lab, test facilities, and 12 Spring Career Fairs As part of the process, researchers have faculty and student expertise, Grace been engaging Iowa companies that Technologies would have been forced 12 ILC Virtual Annual Conference Builds support the new Kent Corporation Feed to spend tens of thousands of dollars to Lean Leaders Mill and Grain Science Complex at Iowa develop that capacity—with no real idea 13 GovTalk–B2G Sales State. In particular, the team is collecting of what the payoff might be. feedback on what tools are needed to 13 For the Record “Getting all the people assembled— monitor machine health of pelletizers the knowledge, the ability to do the 14 Mix of Ancient, Advanced Technologies and milling and rolling equipment. research, the technical understanding of Salvage Older Elevator “We don’t want this work to end up bearings—that was definitely beyond our 15 Persistent Bidding Helps Bowe being just an academic exercise,” said capability by ourselves,” Allen said. Machine Break into Government Hu, whose team already has submitted Novak praised the partnership’s value Contracting journal and conference articles for across the board, including Grace’s publication. “We want this to be 15 Contact Information support for Iowa State internships. practical and useful.” 16 Growing Your Business “This is what every university wants,” The Grace-Iowa State team also is he said. “When they talk about assessing opportunities to file an On the Cover: Venkat Nemani, left, and assistant university innovation and an idea getting invention disclosure and possible patent professor Chao Hu pose next to a test stand commercialized, this is the kind of team application sometime during the year. If where initial vibration research was conducted. you want. You want a company working successful, Grace Technologies would closely with the faculty while you’re CIRAS Mission: Every day we will enhance the commercialize the technology through supporting grad students and others. It’s a performance of industry through applied research, a licensing agreement with Iowa State’s education, and technical assistance. multifaceted system.” Office of Intellectual Property and Technology Transfer. For more information, contact CIRAS is supported in part by the DoC/NIST Manufacturing Extension Partnership, the DoD/DLA Procurement Technical Carey Novak at cenovak@iastate.edu Assistance Program, the DoC/EDA University Center Novak described predictive maintenance or 515-408-4257. Program, and the State of Iowa Economic Growth Committee as the “Holy Grail” for equipment appropriation for the CIRAS Technology Assistance Program. manufacturers. Companies everywhere CIRAS News is published quarterly by the Center for Industrial Research and Service and edited by the CIRAS publications team. Design and production AT A GLANCE is by Hobbs Designs, LLC. Please send questions, comments, or address A Grace changes to ciras.news@iastate.edu.—January 2021 HD20141 Technologies Grace Technologies Articles may be reprinted with the following credit line: “Reprinted from sensor. CIRAS News, Vol. 56, No. 2, a publication of Iowa State University Center FOUNDED: 1993 for Industrial Research and Service.” Please send a copy of the reprint to CIRAS News, 1805 Collaboration Place, Suite 2300, Ames, Iowa 50010-9166. OVERVIEW: Manufacturer of Iowa State University is an Equal Opportunity/Affirmative Action employer. All electrical interface connectors, qualified applicants will receive consideration for employment without regard safety devices, and sensors. to race, color, age, religion, sex, sexual orientation, gender identity, genetic information, national origin, marital status, disability, or protected Veteran EMPLOYEES: 50 status and will not be discriminated against. Inquiries can be directed to the Office of Equal Opportunity, 3410 Beardshear Hall, 515 Morrill Road, IMPACT: Up to $10 million 515-294-7612, email eooffice@iastate.edu. over five years. 2 FOR MORE: www.graceport.com
AT A GLANCE Latham Hi-Tech Seeds FOUNDED: 2009 OVERVIEW: Family-owned seed producer. EMPLOYEES: 48 IMPACT: More than $7 million in new sales, retained sales, and cost reductions over two years. FOR MORE: www.lathamseeds.com Corn sits waiting for shipping at Latham Hi-Tech Seeds. CIRAS Helps Latham Hi-Tech Seeds Have Smooth Spring An Alexander, Iowa, seed company estimates it will gain more than $3 million in new business over the next year, partly because CIRAS helped the company become more efficient in the face of rapid growth. Chris Latham, chief the (earlier) spring in change the way it handles conditioning financial officer for “Sometimes it’s just good 2019 that we had in 2020, and packaging of beans so that the Latham Hi-Tech Seeds, to have that third party we would have been company could begin conditioning even said his company bring everybody together in trouble.” before orders were filled. struggled to keep up with and agree on where the The company reached “What they did for this season was a its orders for soybeans problems are. It was out to CIRAS in summer good first step,” Schneider said. “But if and seed corn in 2019 nice just to be able to 2019 seeking help with the company continues to grow, they’ll as it expanded into new bring everybody in and finding more short-term need to continue to invest.” markets in South Dakota. work through it all.” capacity. That led CIRAS The increased business, Chris Latham said the changes helped the — Chris Latham project managers Marc along with a growing 2020 planting season run smoothly, and Schneider, Andrew trend of farmers seeking he praised CIRAS for playing a valuable Friend, and Steve Wilson to accept their seed as close to the role as an objective outside expert. to review Latham’s operations, diagnose beginning of planting season as possible, “Sometimes it’s just good to have that the bottlenecks, and work with staff to seemed to be creating bottlenecks. third party bring everybody together and correct them. “In 2019, the late spring saved us” from agree on where the problems are,” he Among other things, Schneider’s team being late with orders, said operations said. “It was nice just to be able to bring ultimately recommended that Latham manager Dan Erbes. “If we’d have had everybody in and work through it all.” address some workforce issues and For more information, contact Marc Schneider at maschn@iastate.edu or 563-221-1596. 3
Above, magnetic particles are drawn to the crack sites on a steel drill. Cracks appear as fine yellowish-green lines under florescent light. Below, drill shafts await testing. AT A GLANCE CIRAS Guides Grinding Improvement at Weiler Weiler Inc. A Knoxville-based heavy equipment manufacturer estimates that the company FOUNDED: 2000 retained more than $10 million in sales after CIRAS helped it solve a problem EMPLOYEES: 450 with cracking shafts on a rock drill used in highway construction. OVERVIEW: Manufacturer of heavy- Mark Prachar, a project engineer with “To make rock drills, you need really duty equipment for the asphalt paving Weiler, said the company took control of hard materials,” Utrata said. “When you market. a new process for making components grind that material into final shape, it’s IMPACT: An estimated $10.5 million in for its rock drills in 2018—only to find really tricky to grind it properly. If you retained sales and reduced costs. cracks in the shafts produced. Company don’t do it exactly right, it will overheat, LEARN MORE: engineers, many of them Iowa State then contract too much—and that leads www.weilerproducts.com University graduates, turned to CIRAS for to cracking.” help diagnosing the problem. Prachar said CIRAS expertise helped “We didn’t have the testing equipment the company zero in on correct grinding in-house to know what was happening procedures. Weiler experimented with on the surface or just below the surface new techniques throughout the end of of the part, because we had never done 2018, regularly taking parts to Utrata for it before,” Prachar said. “We were evaluation. changing things, and it wasn’t improving “CIRAS helped us hone in on the specific the result, and we needed to know why.” type of failure that we had,” Prachar Dave Utrata, a CIRAS project manager said. “It helped us develop our grinding who works in Iowa State’s Center for process and in-house NDE inspection “Through the CIRAS analysis, we found Nondestructive Evaluation (CNDE), used techniques.” there is an art to the grinding process,” a combination of ultraviolet light and tiny Prachar said. “The resources that CIRAS Weiler estimates that CIRAS helped the provided helped us find a timely solution magnetic particles to help the company company avoid an estimated $10 million and expertise we can call on again in pinpoint sources of cracking and in lost sales. the future.” understand what was going wrong. For more information, contact Dave Utrata at heydave@iastate.edu or 515-294-6095. 4
Online Orders Are an Elixir Following COVID-19 Collapse A Holstein, Iowa, meat producer now finds itself on the cusp of full-blown e-commerce thanks to a computerized online order system that the company was driven to adopt in response to COVID-19. Tiefenthaler Quality Meats, a family- owned company known for its skinless brats and other meat products, originally sale computer system, enabling approached CIRAS in March seeking online orders to flow directly into help managing the online portion of the company’s existing software. a yearly anniversary sale. However, While business remains down from those conversations soon shifted prepandemic levels, online orders when pandemic safety concerns led now make up roughly one-half of all Tiefenthaler’s to close its retail store to retail sales. customers. Tiefenthaler’s also cancelled Other companies may benefit from the anniversary sale because of the a similar approach, Gormley said. pandemic and its impact on business. Businesses that don’t feel like they Co-owner Shelly Tiefenthaler said have the logistical ability to track and the company was confused about fill online orders right now can still how to continue serving customers mimic larger competitors by offering curbside-only, so she contacted CIRAS the same curbside service. project manager Paul Gormley for help. “In the eyes of the customers, Gormley and other CIRAS-affiliated Tiefenthaler’s looks like a very grown- experts helped Tiefenthaler’s build a up business if it’s doing the same thing new online ordering system. On June as major supermarkets,” Gormley said. 11, the company quietly turned on its “And ‘normal’ e-commerce can come new system and took roughly 350 orders directly out of what it takes to do that.” during the first five days. Tiefenthaler said the company has An order being assembled at “It really has changed a lot of things,” not yet embraced full online sales Tiefenthaler Quality Meats. Tiefenthaler said. “Our staff now stays because shipping companies can’t busy filling online orders, but it’s much yet guarantee timely delivery in a more efficient and organized now. We pandemic-altered economy. But AT A GLANCE will be able to keep offering curbside the company believes it’s on a good Tiefenthaler Quality Meats service for those who don’t want to path, and it is thankful for CIRAS help come in the store for their own personal FOUNDED: 1991 salvaging its sales. reasons. We opened the store back up OVERVIEW: Family-owned meat locker producing, to walk-in customers in late July, but the “CIRAS really helped us figure out among other things, beef, bacon, jerky, and skinless the correct path, the correct way to brats. curbside system is still going strong.” do it,” Tiefenthaler said. “Had I not EMPLOYEES: 20 The new digital storefront works worked with them, I’m not sure where IMPACT: More than $950,000 from a variety of CIRAS with Tiefenthaler’s existing point-of- I would have started.” projects over the last three years. For more information, contact Paul Gormley at gormley@iastate.edu or FOR MORE: www.tqmeats.com 319-721-5357. 5
AT A GLANCE CIRAS Supplier Scouting Helps Bring World Class Industries Business to Iowa FOUNDED: 1953 OVERVIEW: Supply chain management A Hiawatha-based assembly and supply chain integration company expects and assembly company. to see at least $5 million a year in new business after CIRAS facilitated a EMPLOYEES: 200 partnership with an air purification company. IMPACT: Four new jobs and at least $5 million yearly in new sales. World Class Industries started work in CIRAS project manager Adam FOR MORE: www.worldclassind.com October under a contract that quickly Boesenberg used databases and input will see the company producing 24,000 from other CIRAS experts room-sized air purifiers annually for to identify companies “We foresee the Timilon Acquisitions. with the manufacturing business growing nicely out of it than we initially capabilities, capacity, and throughout Iowa.” were looking for.” Timilon, based in Florida, makes quality necessary to meet — George Negron EnviroKlenz Air Systems. The devices Negron said several of the the company’s needs. use special filters and a fan inside a other finalist companies Boesenberg and Putnam ultimately powder-coated cabinet to “remove at could find future work with Timilon as recommended six firms to Timilon, least 99.97 percent of the fine particulate the company expands. “We foresee including World Class Industries (WCI). matter from the air in your home or the business growing nicely throughout The company, which had first learned business.” Iowa,” he said. about Timilon from CIRAS strategy adviser After growing exponentially for several Joy Donald, was chosen at summer’s end. Mike O’Donnell, program director for years, Timilon needed additional the CIRAS Manufacturing Extension Ryan Murphy, director of business capacity. Partnership (MEP), said supplier development for World Class Industries, Tim Putnam, director of the Pappajohn said Timilon liked “our ability to scouting requests usually come through Entrepreneurial Center at North Iowa scale with their business, as well a nationwide MEP system created to Area Community College, said Iowa as our capability to provide ideas help government contractors who can’t entrepreneur and Timilon investor throughout the process to improve the find a qualified U.S. company making John Pappajohn called him in May manufacturability of their product.” what they need. searching for Iowa companies that “Internet searching and online George Negron, Timilon vice possibly could assemble EnviroKlenz directories are great, but sometimes president, agreed. purifiers. Putnam’s organization, which you really need people who understand serves as a CIRAS partner in northern “Everyone CIRAS identified was a great manufacturing,” O’Donnell said. “That’s Iowa, then asked for help searching the candidate,” Negron said. “You not only where CIRAS and our MEP National entire state. saved us time and effort, but we got more Network make a real difference.” For more information about supplier scouting, email the CIRAS Helpline at ciras.info@iastate.edu. Assembling air cleaners at World Class Industries. 6
CIRAS SERVES IOWA: IOWA BY THE NUMBERS IMPACT: More than $2.8 Billion Economic Impact, 2015–2019 LYON OSCEOLA DICKINSON EMMET KOSSUTH WINNEBAGO WORTH MITCHELL HOWARD WINNESHIEK $4.8M – $217,000 $491,000 $2.5M $47.3M $6.9M $1.1M $211,000 $6.7M SIOUX O'BRIEN CLAY PALO ALTO HANCOCK CERRO GORDO $19.8M FLOYD CHICKASAW ALLAMAKEE $11.6M $5.0M $2.4M $336,000 $5.4M $87.5M – $260,000 FAYETTE CLAYTON PLYMOUTH CHEROKEE BUENA VISTA POCAHONTAS HUMBOLDT WRIGHT FRANKLIN BUTLER BREMER $353,000 $16.8M $8.8M – $4.0M $742,000 $15.9M $20.0M $2.2M $750,000 $28.5M WEBSTER BLACK HAWK BUCHANAN DELAWARE DUBUQUE WOODBURY IDA SAC CALHOUN HAMILTON HARDIN GRUNDY $29.0M $18.0M $75.4M $80.0M $169.0M $6.6M $70.4M $34.5M $100,000 $35,000 $34.2M $22.8M TAMA BENTON LINN JONES JACKSON MONONA CRAWFORD CARROLL GREENE BOONE STORY MARSHALL $30.1M $4.1M – $1.1M $146.2M $19,000 $11.3M $4.9M $8.1M $11.1M $182.7M $4.2M CLINTON CEDAR $36.5M HARRISON SHELBY AUDUBON GUTHRIE DALLAS POLK JASPER POWESHIEK IOWA JOHNSON $2.4M $245,000 $2.3M $9.5M $457,000 $24.2M $396.0M $461.0M 13.7M $14,000 $30.0M $279.2M MUSCATINE SCOTT POTTAWATTAMIE CASS ADAIR MADISON WARREN MARION MAHASKA KEOKUK WASHINGTON $113.2M $6.8M – $733,000 $2.2M $14.4M $29.7M $1.5M $1.5M $7.7M LOUISA $5.1M MILLS MONTGOMERY ADAMS UNION CLARKE LUCAS MONROE WAPELLO JEFFERSON HENRY DES MOINES $106,000 $214,000 – $1.2M $1.5M $3.9M $27.5M $4.8M $52.2M $234,000 $16.5M FREMONT PAGE TAYLOR RINGGOLD DECATUR WAYNE APPANOOSE DAVIS VAN BUREN $4.6M $955,000 $2.0M – $73,000 $1.8M $6.0M $31,000 $315,000 $16.5M LEE A small Iowa City agricultural company found market credibility and discovered important product insights after working with CIRAS to research new technology at Iowa State University. Amos Petersen, president of Iowa City-based FarrPro, said the company’s Haven farrowing system uses intermediate infrared and parabolic reflector geometry to create a warm- but-safer environment for piglets and FarrPro’s Haven farrowing system. improve overall health. Initial research, combined with insights from barn plant, as well as yearly sales of more have been a struggle for a company workers where some testing took place, than $1.3 million. our size.” led to subsequent studies and several Petersen said the Iowa State research FarrPro is one of more than 4,100 product improvements. According to helped FarrPro’s seven-person team companies that CIRAS has worked with Petersen, Iowa State research revealed prove the worth of its technology for over the past five years. Combined, those that Haven can lower the prewean investors and potential customers. projects produced an economic impact mortality for piglets, reduce disease, and of more than $2.8 billion. save energy for producers in comparison “The value we received was worth to the use of traditional heat lamps. several times more than what we paid For more information on working for the study,” Petersen said. “It was with Iowa State faculty and students, FarrPro estimates that the project great that CIRAS was able to cofund visit https://www.ciras.iastate.edu/ eventually will create up to 13 jobs and that, because, quite frankly, it would ciras_services/contract-research. $2 million in investment at the company’s 7
CIRAS SERVES IOWA: BY THE NUMBERS JOBS: More than 29,000 Added or Retained Jobs Added or Retained, 2015–2019 LYON OSCEOLA DICKINSON EMMET KOSSUTH WINNEBAGO WORTH MITCHELL HOWARD WINNESHIEK – – – 9 42 221 164 29 SIOUX O'BRIEN CLAY PALO ALTO HANCOCK CERRO GORDO 1 141 45 FLOYD CHICKASAW ALLAMAKEE 70 15 39 3 126 374 – – FAYETTE CLAYTON PLYMOUTH CHEROKEE BUENA VISTA POCAHONTAS HUMBOLDT WRIGHT FRANKLIN BUTLER BREMER 4 335 25 – 11 24 143 73 9 – 453 WEBSTER BLACK HAWK BUCHANAN DELAWARE DUBUQUE WOODBURY IDA SAC CALHOUN HAMILTON HARDIN GRUNDY 3,004 389 124 613 1,281 1,338 110 1 – 216 326 23 TAMA BENTON LINN JONES JACKSON MONONA CRAWFORD CARROLL GREENE BOONE STORY MARSHALL 569 46 – 15 1,519 – 221 35 96 46 507 15 CLINTON HARRISON SHELBY AUDUBON GUTHRIE DALLAS POLK JASPER POWESHIEK IOWA JOHNSON CEDAR 209 11 14 19 135 2 242 4,175 3,634 195 4 533 5,008 SCOTT MUSCATINE POTTAWATTAMIE CASS ADAIR MADISON WARREN MARION MAHASKA KEOKUK WASHINGTON 126 140 1 – 44 14 153 5 15 46 LOUISA MILLS MONTGOMERY ADAMS UNION CLARKE LUCAS MONROE WAPELLO JEFFERSON HENRY 56 DES MOINES 3 6 – 35 28 – 20 27 463 3 389 FREMONT PAGE TAYLOR RINGGOLD DECATUR WAYNE APPANOOSE DAVIS VAN BUREN 53 21 11 – 2 3 97 – 6 309 LEE T wo Iowa companies impacted significantly when the COVID-19 pandemic arose last spring nevertheless were able to add or retain a combined 170 jobs after CIRAS helped them partner to make personal protective equipment (PPE). Brownmed of Spirit Lake and Metalcraft of Mason City were two of many companies CIRAS contacted last March in response to looming Iowa PPE shortages as the Face shield material at Metalcraft. coronavirus raged. To help PPE production ramp up quickly, CIRAS assisted more than 100 jobs and added nearly 70 officer at Metalcraft. “It was nice to Metalcraft and Brownmed with tooling additional workers. have CIRAS to bounce ideas off of and and hard-to-get raw materials. These two great to work with Brandon and his team “Like many companies, in mid-March companies alone ultimately produced far at Brownmed.” we essentially saw our core business more than 1 million face shields, with some dissipate overnight,” said Brandon Last year, CIRAS worked with companies donated to local charities and others sold Rodriguez, vice president of production across Iowa to add or retain more than to hospitals and state agencies. management for Brownmed. “If it weren’t 29,000 jobs. Those projects generated an In addition to helping fill medical needs, for the introductions CIRAS made, it economic impact of more than $2.8 billion. both companies used the face shield would have been far more challenging business to keep their workers employed For more information, visit for us to find the needed resources.” during the demand-cratering pandemic. www.ciras.iastate.edu/covid-19/ “Obviously, we’re thrilled with how it supply-chain-disruptions/. Combined, the two companies saved went,” said Kyle Bermel, chief operating 8
CIRAS SERVES IOWA: BY THE NUMBERS CONNECTIONS: More than 4,100 Distinct Clients Served Distinct Clients Served, 2015–2019 LYON OSCEOLA DICKINSON EMMET KOSSUTH WINNEBAGO WORTH MITCHELL HOWARD WINNESHIEK 14 4 21 10 17 9 14 15 SIOUX O'BRIEN CLAY PALO ALTO HANCOCK CERRO GORDO 25 24 27 FLOYD CHICKASAW ALLAMAKEE 70 18 27 14 24 53 14 13 FAYETTE CLAYTON PLYMOUTH CHEROKEE BUENA VISTA POCAHONTAS HUMBOLDT WRIGHT FRANKLIN BUTLER BREMER 19 28 19 12 18 10 19 18 11 7 20 WEBSTER BLACK HAWK BUCHANAN DELAWARE DUBUQUE WOODBURY IDA SAC CALHOUN HAMILTON HARDIN GRUNDY 46 114 19 15 121 108 14 9 11 20 17 5 TAMA BENTON LINN JONES JACKSON MONONA CRAWFORD CARROLL GREENE BOONE STORY MARSHALL 18 22 13 15 365 7 11 45 16 26 207 34 CLINTON HARRISON SHELBY AUDUBON GUTHRIE DALLAS POLK JASPER POWESHIEK IOWA JOHNSON CEDAR 59 10 20 22 8 34 59 786 35 27 23 149 312 SCOTT MUSCATINE POTTAWATTAMIE CASS ADAIR MADISON WARREN MARION MAHASKA KEOKUK WASHINGTON 49 140 18 12 14 41 51 23 10 23 LOUISA MILLS MONTGOMERY ADAMS UNION CLARKE LUCAS MONROE WAPELLO JEFFERSON HENRY 10 DES MOINES 20 20 7 19 12 7 9 34 26 15 45 FREMONT PAGE TAYLOR RINGGOLD DECATUR WAYNE APPANOOSE DAVIS VAN BUREN 9 37 7 6 9 8 20 8 8 34 LEE I owa manufacturers know that com- petition eventually will require them to learn more about automation technology, Ramco employee educating at a CIRAS event. including robotics and vision systems, Hank Norem believes. However, it remains difficult for most of them to make the leap. “A lot of companies are looking at this technology, but they’re not adopting it yet,” said Norem, president of West Des Moines-based Ramco Innovations. “Working together with CIRAS, we can continue to educate companies on then evaluate it before investing. With help from partners, CIRAS hosted six automation and hopefully make them Digital Manufacturing Lab tours between Other CIRAS technology partners stronger in the long run.” September 2019 and March 2020, when include Computer Aided Technology Ramco is one of three partners helping COVID-19 closed the physical space. (a 3D printing and scanning company CIRAS expose Iowa manufacturers After shifting to virtual, CIRAS hosted in West Des Moines) and MakuSafe to cutting-edge technology through more than 20 online technology events (a West Des Moines safety, data, and Iowa State’s Digital Manufacturing Lab between March and November 2020. analytics company). powered by Alliant Energy. CIRAS has worked with more than 4,100 Chris Hill, director of the CIRAS Opened in September 2019, the lab companies over the past five years on Technology Assistance Program (TAP), helps Iowa companies filter the projects with an economic impact of said local partnering relationships help noise surrounding new technologies. more than $2.8 billion. CIRAS access new technology while Manufacturers can explore options, find meeting an important goal of connecting For more, visit the right application for their business, companies and keeping investment https://newswire.ciras.iastate.edu/ dollars inside Iowa. category/digital-manufacturing-lab/. 9
CIRAS SERVES IOWA: BY THE NUMBERS WORKFORCE PIPELINE: More than 2,400 Interns Placed Iowa State University interns at Iowa companies, 2019 LYON OSCEOLA DICKINSON EMMET KOSSUTH WINNEBAGO WORTH MITCHELL HOWARD WINNESHIEK – 2 15 1 12 1 5 4 SIOUX O'BRIEN CLAY PALO ALTO HANCOCK CERRO GORDO 1 – 9 FLOYD CHICKASAW ALLAMAKEE 2 5 7 5 4 17 6 8 FAYETTE CLAYTON PLYMOUTH CHEROKEE BUENA VISTA POCAHONTAS HUMBOLDT WRIGHT FRANKLIN BUTLER BREMER 4 4 7 1 10 1 4 12 9 3 6 WEBSTER BLACK HAWK BUCHANAN DELAWARE DUBUQUE WOODBURY IDA SAC CALHOUN HAMILTON HARDIN GRUNDY 13 39 8 11 14 19 7 3 5 9 11 4 TAMA BENTON LINN JONES JACKSON MONONA CRAWFORD CARROLL GREENE BOONE STORY MARSHALL 3 10 3 – 150 5 2 14 3 23 783 49 CLINTON HARRISON SHELBY AUDUBON GUTHRIE DALLAS POLK JASPER POWESHIEK IOWA JOHNSON CEDAR 7 5 2 6 1 2 23 773 6 4 31 21 30 SCOTT MUSCATINE POTTAWATTAMIE CASS ADAIR MADISON WARREN MARION MAHASKA KEOKUK WASHINGTON 43 13 2 4 2 6 33 4 4 7 LOUISA MILLS MONTGOMERY ADAMS UNION CLARKE LUCAS MONROE WAPELLO JEFFERSON HENRY 1 DES MOINES 1 4 1 11 4 1 – 7 7 1 12 FREMONT PAGE TAYLOR RINGGOLD DECATUR WAYNE APPANOOSE DAVIS VAN BUREN – 2 5 – – 1 7 – 5 4 LEE H enderson Products is a big believer in its partnership with Iowa State University engineering students. Last fall, the Manchester manufacturer of multipurpose equipment for heavy- duty work trucks launched three yearlong projects with Iowa State seniors. The capstone projects involved teams of senior engineering students working to improve the ergonomics of Iowa State alumni working at Henderson Products in Manchester. equipment on a dump body production line and studying the safest way for But Henderson Products has a deeper capstones and internships, we’ve employees to remove parts from large interest as well, Sigwarth said. Working recruited some very strong talent from laser tables. with Iowa State students gives Iowa State University. This will be crucial Jerry Sigwarth, continuous improvement the 450-person company a perfect as we continue to improve, engage, and engineering manager at Henderson, opportunity to present its best face to a grow as a company.” said capstone projects are a perfect valuable future workforce. Iowa State University sent more than way for the company to focus additional “We take a lot of pride in being 2,400 interns to hundreds of Iowa resources on nagging problems or test customer- and results-driven,” Sigwarth companies like Henderson last year. the feasibility of new ideas. Students can said. “Any opportunity to gain exposure Those students were employed at help answer important questions “that and help potential talent understand businesses stretching through 91 wouldn’t normally make it to the top of what Henderson does, what the culture Iowa counties. the priority list.” is, and what the opportunities are For more, visit www.ciras.iastate.edu/ helps set us up for the future. Through ciras_services/capstone-design/. 10
UPCOMING EVENTS COVID-19 Assessment Helps Larson Ensure Best ■ Weekly COVID-19 Roundtable for Practices during Pandemic Manufacturers Tuesdays Like most responsible companies navigating a pandemic, Larson Manufacturing 7:30 a.m. worked hard to secure its Lake Mills manufacturing facility against COVID-19. Among Online presentations on a other things, the company posted signs, upgraded its cleaning procedures, and weekly topic followed by installed social distancing barriers. But was that enough? questions and answers. To make certain, Larson last summer became one of Iowa’s first companies to receive ■ Virtual Lean Coffees a CIRAS virtual COVID-19 Preparedness 3rd Friday each month Assessment. CIRAS can offer these and 9:00 a.m. to 10:15 a.m. other assessments at no cost thanks to funding from the Coronavirus Aid, Relief, and ■ Using beta.SAM.gov Economic Security (CARES) Act through the February 15, 2021 NIST Manufacturing Extension Partnership. Webinar exploring the government’s website for “Even though we felt we were doing finding potential bidding pretty well, we thought we’d seek out the opportunities. opportunity to find out if there were any gaps we needed to fill,” said Brian Throne, ■ Capabilities Statement Iowa operations manager for the door and February 24, 2021 window company. “I think we learned a lot.” Webinar explaining what CIRAS experts spent several hours over a capabilities statement is, the course of three weeks evaluating the why it’s important, and how company on 65 criteria spread across to draft and share one. 13 areas. Company leaders used video conferencing, email, and a secure file- Updated signage at Larson Manufacturing. ■ Sales Strategy for 2021 sharing tool to discuss COVID-19 policies February 26, 2021 and procedures and to share photos and videos with the CIRAS team. AT A GLANCE Webinar to help leaders understand the key The result? CIRAS experts identified several Larson Manufacturing Co. dimensions of strategy. areas where Larson could do things such FOUNDED: 1954 as increase visual controls at entry points OVERVIEW: Largest manufacturer of storm ■ Subcontracting and aid cleaning efforts by removing some doors and storm windows in the United April 7, 2021 nonessential items from work areas. States. Webinar to help businesses EMPLOYEES: 240 in Iowa understand subcontracting CIRAS project manager Marc Schneider IMPACT: Peace of mind, better plan for a opportunities and where to described the changes as “minor things,” future event. such as upgrading quickly assembled find them. FOR MORE: www.larsondoors.com social distancing markers (8.5” by 11” printouts taped to walls) to larger, more For details on these permanent signage. Throne said Larson also plans to improve and other events, visit the clarity of some written policies. www.ciras.iastate.edu/ “Part of our purpose was just to validate events-workshops. that what they were doing made sense, and “This was a really comprehensive review,” they weren’t missing anything,” Schneider he said. “I think we’ll come away from this said. “The biggest thing was helping them with a better plan for any future event.” transition to the long term.” For more about COVID-19 assessments, contact Marc Schneider at maschn@iastate.edu or 563-221-1596. 11
Spring Career Fairs ■ Business, Industry, and Technology Career Fair Thursday, February 25, 2021 10:00 a.m. to 5:00 p.m. Virtual (short, online video meetings) (focuses on business, liberal arts and sciences, and human sciences) CONTACT: bcs@iastate.edu Colonel Candice Frost appearing at the ILC Virtual Annual Conference. ■ Design Career Fair Wednesday, February 24, 2021 10:00 a.m. to 5:00 p.m. ILC Virtual Annual Conference Builds Lean Leaders Virtual Good leadership should be purposely developed in yourself and others by CONTACT: building strong relationships with those on your team, an Iowa-born U.S. Army designcareers@iastate.edu colonel told more than 200 Iowa business leaders in October. ■ Engineering Career Fair Col. Candice Frost was the keynote speaker What matters is that you provide purpose, Tuesday, February 16, 2021, and for October’s first-ever Annual Virtual direction, and, most importantly, motivation Wednesday, February 17, 2021 Conference by the Iowa Lean Consortium for others.” 10:00 a.m. to 5:00 p.m. (ILC). The event, customarily the largest Good bosses know their people and what Virtual single educational event put on by CIRAS, they’re able to do, she said—meaning they was held online for the first time in 2020 due CONTACT: ecs@iastate.edu know how to put each person in a position to COVID-19. to succeed. ■ People to People Career Fair In addition to Frost, the conference Tuesday, February 23, 2021 Frost acknowledged that some managers included six breakout sessions covering, are required by circumstance to be 10:00 a.m. to 5:00 p.m. among other things, how the Omaha “transactional” leaders, always focused on Virtual Public Power District used Lean to create maintaining the status quo and doing what’s (focuses on human/social services, a strong problem-solving culture and a necessary to keep their team in line. But she education, health/wellness, government, video summary of continuous improvement urged her audience, when possible, to “shift and hospitality; hosted by the Colleges projects completed by Cardinal Glass. your mindset from a bureaucratic checklist of Human Sciences and Liberal Arts and Involving frontline workers in problem- to become a broader leader. Those are the Sciences) solving sessions propelled success, said bosses you forever treasure, because they CONTACT: hscareers@iastate.edu Brian Kramer, a substation manager for the saw something in you that you didn’t see in power district. “We would take that quick yourself.” ■ Teacher Education Fair win, and we would implement it instantly,” Monday, March 1, 2021 Frost urged listeners to mentor others he said. “Those quick wins were really Noon to 4:00 p.m. and seek out mentors themselves—even important.” Virtual during “adverse times.” Find a mentor now, CONTACT: hscareers@iastate.edu Col. Frost, originally from Muscatine, she said, and “you’ll truly demonstrate currently serves as director of foreign commitment to your craft.” Students wait for interviews during a intelligence for the Army G-2 within The ILC began offering a mentor-matching prepandemic career fair. U.S. Army headquarters. Speaking from service for its members at the end of Washington, D.C., she called on Iowans 2019. ILC program director Tracy Schuster to work at building leadership skills and said the mentoring process recently was encouraging the trait in others. simplified through the ILC’s own Plan, Do, “Each of you has the opportunity to grow Check, Act process. Would-be mentees this skill,” she said. “Leaders are made, not now can search a database and contact a born. No one comes out of the womb a chief potential mentor directly to inquire about executive or a colonel in the U.S. Army. the possibility of working together. For more, contact Tracy Schuster at tschust@iastate.edu or 515-715-0164. 12 (For conference recordings, visit the Members Only area of www.ciras.iastate.edu/iowalean.)
GOVTALK–B2G SALES UEA Finds Success through Proposal Process FOR THE RECORD Key pillars of the CIRAS support A Waverly manufacturer of slip rings landed structure continue to be reinforced a $1.7 million contract from the Federal AT A GLANCE by federal agencies so CIRAS can Aviation Administration after CIRAS helped maintain access to its vast network the company understand government bidding United Equipment of expertise. requirements and learn how to write a Accessories CIRAS received its annual award from formal proposal. FOUNDED: 1952 the National Institute for Standards OVERVIEW: Family-owned and Technology (NIST) Manufacturing Hemen Dattani, sales director for United company specializing in a Extension Partnership (MEP). As part Equipment Accessories (UEA), was tasked wide variety of rotary motion of a long-term agreement, $2.1 million last March to explore federal contracting products. of federal money is matched with opportunities so UEA could leverage a newly EMPLOYEES: 145 CIRAS funds to create an MEP program forged research and development partnership budget of $4.2 million. In addition, as IMPACT: A new contract to expand design capabilities and make the part of the Coronavirus Aid, Relief, and worth $1.7 million. Economic Security (CARES) Act, CIRAS company competitive in new markets. He FOR MORE: www.uea-inc.com received $595,000 to help small and turned to the CIRAS Procurement Technical medium-sized manufacturers respond Assistance Center (PTAC) for help. to COVID-19. During 2020, CIRAS also won competitive awards in the amount CIRAS government contracting specialist Melissa Burant worked with Dattani of $200,000 to increase the adoption of for weeks helping him learn how to interpret the government’s requirements. Industry 4.0 technologies and $53,000 The nature of the project meant that UEA had to do more than simply provide to create a regional service center a product—the company would need to write a proposal explaining how it supporting the MEP National Network would meet the FAA’s needs. in food manufacturing. With Burant’s help, Dattani found a proposal-writing class. He then worked a The U.S. Defense Logistics Agency week of 15-hour days to write and submit UEA’s proposal. recently renewed CIRAS as Iowa’s Procurement Technical Assistance Burant described the collaboration as a perfect example of how companies Center (PTAC). CIRAS will receive can make the most of PTAC assistance. roughly $700,000 during the next fiscal year. The money is matched with CIRAS “The greatest difference I have observed between those companies who see funds to provide nearly $1.2 million success versus those who don’t is that successful companies tend to work of assistance to Iowa businesses in with us side by side and understand the importance of tapping into PTAC as a navigating the world of government resource,” she said. “We may not always have the answers, but we’re a great contracting. guiding light to show you the way.” CIRAS last year received $1.4 million through the Iowa Legislature’s Dattani praised PTAC’s expert counsel. Economic Development Appropriations “This is selling by writing,” Dattani said. “It’s very different in many ways, and Bill to fund our Technology Assistance Program (TAP), which provides totally new for us. Melissa was very instrumental in guiding me through each expertise and funding to businesses step of the way.” to lessen the risk of adopting new For more information, contact Melissa Burant at mmburant@iastate.edu technologies. or 563-726-9958. Finally, CIRAS has received another The United Equipment Accessories Team. $138,000 installment of a grant from the federal Economic Development Administration (EDA) to assist rural communities in their search for skilled workers. The initiative, known as the Iowa Workforce Innovation Network (iWin), is matched with CIRAS funds and other grants for a program budget of $276,000. Additionally, the CARES Act is providing another $150,000 in FY2021 for workforce-related programs to assist with pandemic recovery. 13
AT A GLANCE Mix of Ancient, Advanced Technologies Premier Real Estate Services Salvage Older Elevator FOUNDED: 2010 EMPLOYEES: 6 A downtown Des Moines apartment building avoided a costly elevator OVERVIEW: A full array of real estate replacement last year after CIRAS helped its owners recreate an services for investors, owners, and tenants. essential piece of safety equipment. IMPACT: Delayed costly purchase of a new elevator cab. Investors bought the aging, 11-story building at 600 East Fifth Street in LEARN MORE: www.premier-midwest.com Des Moines in 2013. They then renamed it The Lyon and spent two years remodeling it into 103 new apartments. A problem soon became apparent, however, in that something important seemed to have been lost during the sale. An account manager with The Lyon’s elevator maintenance company estimated that equipment there dates back “at least 50 years”—to a time when elevator shafts were built with key-controlled “safeties” located roughly at each floor to catch the car in case a cable broke. Once engaged, whether via accident or test, those safeties could only be reset by turning a key in a slot in the elevator car floor. A key that The Lyon no longer had. “The cab is original to the building, and they no longer manufacture that model,” said Brittany Jackson, an account manager with Premier Real Estate Services. Borrowing a key soon became untenable, so “we looked online. We looked on eBay. Nothing. Recreating one was the only option.” Premier contacted CIRAS for help, but physical limitations blocked the first attempt to create a 3D scan of the keyhole. So experts reverted to much older technology: they stuffed modeling clay into the mechanism, then scanned the removed clay and used it to create a 3D design. Chris Hill, director of the CIRAS Technology Assistance Program (TAP), then worked with CIRAS project manager Jake Behrens to clean up the computerized design and 3D print a plastic prototype. After a few modifications, CIRAS used its metal 3D printer to create a new permanent key. “This just shows that these technologies are not just for manufacturers,” Hill said, arguing that many technologies found in Iowa State University’s Digital Manufacturing Lab powered by Alliant Energy also could prove helpful in other ways, such as when builders seek to recreate old architectural features. “There are a lot of other areas where they can be put to use.” For Jackson, the project was a lifesaver. “Without this option, I’m not quite sure where the owners of our building Lyon on-site building manager Cody Hiles turns would be,” she said. “We got severely lucky in finding CIRAS.” the key in front of a mural inside an elevator. For more information, contact Chris Hill at chhill@iastate.edu Smaller photos show the keyhole, a clay molding or 515-313-8251. used for scanning (top left), and two plastic prototypes. 14
CONTACT INFORMATION Persistent Bidding Helps Engage. Educate. Embed. Bowe Machine Break into Since 1963, we have delivered proven services to enhance the performance of industry. Our approach—Engage. Educate. Embed.—creates specific solutions Government Contracting that allow each business and its community to prosper and grow. Coupled with a satisfaction guarantee, our typical client has achieved a 200% ROI. Clients have A Bettendorf machine shop landed government reported an economic impact of more than $2.8 billion over the past five years. contracts worth more than $100,000 after CIRAS Locate your county to find your best introduction to CIRAS. helped a new supervisor delve deep into the In addition to four regional account managers, CIRAS has six regional intricacies of government bidding. government contracting specialists,* a statewide account manager Michael Bigsby had been working at Bowe Machine for the food industry, and one for economic development. More staff Company for roughly six months when he proposed information can be found at www.ciras.iastate.edu/staff.asp. that the company pursue government contracts. Bigsby had been involved in quoting government jobs for a CIRAS PARTNERS previous employer, but he had never played a major • Iowa State University role in the bidding process. · Center for Crops So, he sought help understanding the procedures. Utilization Research · Center for Melissa Burant, a government contracting specialist Nondestructive with the CIRAS Procurement Technical Assistance Center Evaluation (PTAC), worked closely with Bigsby for several months · College of Engineering to get Bowe registered with government agencies and NORTHWEST · Department of certified to see sensitive information. She helped him Derek Thompson Economics get set up with CIRAS BidMatch, a computer system that thompson@iastate.edu • 515-419-2163 · Department of sorts government bidding opportunities based on user- Mary Zimmerman* Environmental Health defined criteria, and continued tweaking the settings and Safety maryz@iastate.edu • 515-450-1278 until Bigsby’s daily email load was manageable. · Engineering Career The two kept talking over several months as Bigsby NORTHEAST Services bid roughly 50 to 60 jobs without ever receiving a Steve Wilson · Extension and contract. Eventually, wilsons@iastate.edu • 515-620-6036 Outreach Julie Fagle* perseverance paid off in several jobs producing AT A GLANCE jafagle@iastate.edu • 319-310-8612 · Iowa Grain Quality Initiative welding fixtures for Bowe Machine Co. · Meat Science SOUTHWEST military machine shops. Extension FOUNDED: 1956 Paul Dunnwald “It seemed like once we dunnwald@iastate.edu • 515-509-1377 · Polymer and Food OVERVIEW: Family-owned job Protection Consortium got our name out there Jodi Essex* and contract machine shop. · Structural Engineering and we won one, then jodir@iastate.edu • 515-509-0769 EMPLOYEES: 70 Research Laboratory I started getting phone Justin Niceswanger* calls,” Bigsby said. IMPACT: More than $100,000. jnice@iastate.edu • 515-509-9565 • Alliant Energy FOR MORE: • Iowa Area Development “He kept showing up,” SOUTHEAST Group www.bowemachine.com Burant said. “He didn’t Glenn Volkman • Iowa Association of let up on the gas after gvolkman@iastate.edu • 515-205-3786 Business and Industry our first conversation. He put it into practice, and he has Melissa Burant* • Iowa Economic continued to invest in the process.” mmburant@iastate.edu • 563-726-9958 Development Authority Burant praised the company’s determination, and Bowe Samantha Ferm* • Iowa Farm Bureau siferm@iastate.edu • 319-333-9558 praised Burant’s quality advice. • Iowa Sustainable STATEWIDE Business Forum “Melissa has been a great help,” Bigsby said. “Anytime I have a question about whether I’m doing something Brenda Martin (Food Industry) • North Iowa Area bkmartin@iastate.edu • 515-570-5282 Community College right, I call her.” Mark Reinig (Economic Development) • Northeast Iowa For more information, contact Melissa Burant mreinig@iastate.edu • 515-231-4150 Community College at mmburant@iastate.edu or 563-726-9958. 1805 Collaboration Place, Suite 2300, Ames, Iowa 50010-9166 Phone: 515-294-3420 • ciras.info@iastate.edu • www.ciras.iastate.edu 15
Center for Industrial Research and Service 1805 Collaboration Place, Suite 2300 Ames, Iowa 50010-9166 www.ciras.iastate.edu GROWING YOUR BUSINESS Digital Manufacturing Lab: A Smart Resource for Iowa Manufacturers By Abhay Grover The manufacturing world has changed. Isolated purchasing decisions. We also can assist proof-of-concept mechanical systems are being replaced by real-time, development and help with implementation. interconnected, and self-operating systems that share Our partnerships with technology leaders around the state data among themselves. This is the fourth industrial help CIRAS give our clients access to the latest technology revolution and the future of operational efficiency. resources. Currently, our lab houses state-of-the-art 3D Is your manufacturing operation ready? printers, metrology-grade laser scanners, robots, sensors, vision systems, and more. We work continually to develop CIRAS, working closely with our technology partners, is new and pertinent demonstration units to explain what working hard to get you there. the technology can do—always guided by the direct In September 2019, we opened Iowa State University’s feedback we get from Iowa manufacturers. Recent Digital Manufacturing Lab powered by Alliant Energy. The technology additions include contact tracing and density lab helps companies experience, identify, and implement mapping sensors. cutting-edge Industry 4.0 manufacturing technologies. If you’re not sure where to start, CIRAS has a robust We help businesses succeed by solving business Industry 4.0 technology assessment process to help problems and making sure they have a plan that supports companies identify and prioritize potential needs. This technology beyond the initial implementation. covers areas such as cybersecurity, augmented and virtual CIRAS helps companies explore new technologies reality, big data analytics, robotics, industrial automation, through educational events, webinars, and on- system integration, Internet of things, and 3D printing. site demonstrations. We work with our Digital Lab Industry 4.0 is here to stay, and new technologies can technology partners to help companies understand solve real business problems in new ways. CIRAS can areas where technologies can provide new solutions to help you find those solutions with a minimum of risk. old problems. We help companies test the possibilities, then we connect them with providers and support any For more information, contact Abhay Grover at agrover@iastate.edu or 515-509-1485. 16
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