Cuyahoga Community College’s Manufacturing Center of Excellence works to fill the skills gap

Tri-C manufacturing center of excellence

In June, I met with Alicia Booker, vice president of manufacturing, and Alethea Ganaway, program manager additive manufacturing & Ideation Station, of Cuyahoga Community College’s Workforce, Community and Economic Development division at the Metro Campus. Booker says, “We take a manufacturing systems approach and not a product approach. We don’t just focus occupationally on the need to fill a gap then three months later the need arises again due to churn.”

For this team, it’s all about workforce development and creating a skilled workforce. More than 3,500 students are attending the workforce programs, including youth, adults interested in a career transitions, students who already have a degree but are returning to upgrade skills, older adults interested in a second career, employees who need additional training for their current role, and job seekers interested in starting a career.

Booker moved to Ohio two years ago from Pennsylvania to accept the position. Ganaway was moved from Tri-C’s robotics program to additive manufacturing in order to write the grant to fund the program. Now, two years later, the fruits of their labor are paying off in the Manufacturing Center of Excellence (MCoE).

Booker says, “We offer a unique brand of training – short-term through two-year degree plus transfer opportunities. Classes are offered in environments that meet the needs of the students and customers — day, evening, weekend, and bootcamp formats, full- and part-time training, and now we can offer onsite training through the Citizens Bank Mobile Training Unit. Our programs are comprehensive, offering exploration and career exposure to students as young as eight years old through our Nuts & Bolts Academy, middle and high school visits (via the mobile unit), and our college credit plus K-12 initiative.”

This is what the impressively outfitted MCoE contains:Tri-C manufacturing center of excellence scanner

  1. A shop that houses CNC equipment
  2. An integrated systems line with Fanuc robots that launched in June 2017 (Students can become a certified production technician in eight weeks, including program automation, PLCs, and visual inspection for quality control.)
  3. A 3D printing lab that houses a Faro scanner and two printers that can print biomedical-grade devices
  4. A PLC training line with both Allen-Bradley and Siemens systems that launched In August 2017 (Students can earn an international certification for Siemens Mechatronics Systems, mainly used by European companies, since there are more than 400 German companies in northeast Ohio, while Allen-Bradley is more common in The United States. Some companies, such as Ford, use both systems in different portions of the plant. The training line includes a PLC station with hydraulic and pneumatic boards and a robotic arm.)
  5. A rover for virtual-reality training and integrated gaming
  6. A Fab Lab, a maker space for community and international collaboration (it houses a classroom; a Techno CNC router; an embroidery machine; a small mill for engraving, heat presses for T-shirts, hats and mugs; a laser engraver; and a vinyl cutter.)
  7. A mobile unit that can go to businesses, events and schools for teaching and demonstration opportunities in a nine-county area that launched in February 2017 (The trailer fits 10 students and instructors; is WiFi, laptop and software equipped; has its own generator; has plugs for different amperages; and can be deployed with electrical, welding, CNC, mechanics and 3D printing equipment. The lab already has been deployed to the 2017 IndustryWeek Manufacturing & Technology Conference & Expo, a workforce summit, Crestwood Local Schools, and Boys & Girls Club of Cleveland.)

According to Ganaway, “The Additive Manufacturing program includes not only 3D printing, but we teach students how to reverse engineer parts, 2D and 3D design, 3D scanning, inspection and other technologies related to additive manufacturing.  Additive manufacturing is not just related to manufacturing; it includes other disciplines, as well, such as medical.  Some of the projects include 3D printing prosthetics for veterans at the VA who are disabled.”

The college offers training by which students can earn college credits and industry certifications. In the welding training, they learn MIG, TIG, and stick welding. Right Skills Now affords students with CNC training in manual and automated machining. They train on Haas CNC mills and lathes, and on Bridgeport manual machines. The 3D/additive manufacturing training is in digital design, and students receive training in multiple 3D printing technologies, including the use of 3D printers, scanners, and other equipment available through the Ideation Station where they can work with a techno router, laser engraver, etc. In Mechatronics, students learn techniques in mechanical, electrical, computerization, and gain an understanding of how these systems work together. Finally, as a certified production technician, students are prepared to begin career opportunities in manufacturing and earn four industry certifications in areas of safety, manufacturing processes and production. This is a hybrid training program that includes training on the integrated systems training equipment to prepare them for occupations in material handling, assembly and production.

To stay connected to industry, the program has several advisory committees made up of industry professionals from the welding, machining, electrical, mechanical, 3D printing and transportation sectors. They also have specific employer-based programs, including First Energy, Swagelok and ArcelorMittal, who have advised the college on customized programs that lead to employment with their companies. Local businesses, such as Cleveland Job Corps, Cleveland Municipal School District, Towards Employment, Boys & Girls Club, Ohio Means Jobs, Ford, General Motors, Northeast Ohio Regional Sewer District, Cuyahoga Metropolitan Housing Authority, NASA, Arconic, Charter Steel, and others, utilize the program’s services.

The program, says Booker, helps to meet the growing demand for a skilled workforce by “working to strengthen the region by supporting the existing efforts of our partners and by addressing the needs we hear from employers for a skilled workforce. We provide a quick response for new skills by developing new programs and training modalities. We also are working with schools and youth-serving organizations to enhance the talent pipeline that industry needs.” She continues by sharing that the most common challenge that she sees manufacturing facing is “the alignment of skills — commonly referred to as the skills gap. The impact of technology on the industry is also a challenge as industry works to keep up with the growth of technology, and we (as a training institution) work to keep up with the projected needs for skilled workers.”

Tri-C manufacturing center of excellence mechatronics

Q&A with Bob Juran, vice president, sales and marketing, Terves Inc.

Terves' S-Comp product used for creation of armor plating for the U.S. Army's humvees
Terves’ S-Comp product used for creation of armor plating for the U.S. Army’s humvees

My goal with this column is to bring to light all the small manufacturers making a small product for big applications and using big ideas with a huge does of innovation. We all use products every day in our houses, cars and at work. But, do we think about where they come from, who makes them and all of the R&D that goes into them? Manufacturing is an amazing industry that utilizes cutting-edge technology and innovative, creative, critical and analytical thinkers as well as skilled production staff who run the machines and equipment on the floor that take these products from an idea and turn them into tangible, saleable goods.

When was the company founded, by whom and why?

Powdermet was founded just over 20 years ago. We had a 20-year celebration here in August 2016. Powdermet’s focus is on the creation of new, nano-engineered materials-science-based technologies. During those 20 years nearly $50 million has been invested in materials-science research here, and Powdermet has earned dozens of patents, three R&D 100 Awards, commercialized 18 trademarked materials, been named to the Inc.5000 list twice (including last year), been named to the Weatherhead 100 multiple times, and served as the platform for 11 new company launches. Terves is one of those launches. Terves technology is based on Powdermet work done for the Department of Defense, repurposed and modified to meet specific needs in the oil and gas industry. Terves was founded in 2013.

Why did you locate in Euclid, Ohio?

This goes back in history, well prior to me, but I believe there were two issues at play here. First, Andy Sherman, our CEO, was originally from this area and relocated back here from California to make this our headquarters. Second, this amazing building and site become available. We occupy what was the TRW World R&D Headquarters. Our building alone is a historical landmark, besides being ideal for our business profile. The other key aspect of locating here was that this region has a broad range of materials suppliers that are well versed in two key areas for us: polymer and elastomeric technology and high-performance alloys, driven by the birth of the rubber industry in Akron and a strong aerospace/military development industry throughout Northeast Ohio.

What do you make?

Essentially, we “make materials do more.” We create technologies, starting at the atomic level, to meet the needs of industry and government. So, we cover the gamut from lightweight materials used for aerospace, armor plating materials used for the military, thermal insulating and radiation shielding composites, nano-coatings (microscopic coatings), reinforced composites, highly engineered and reactive alloys, and high-surface hardness composites. On a given day here you might find a prototype rocket motor on one desk, a high-performance electrical capacitor on another, and a pallet of dissolvable tubular alloy being loaded on a truck.

What types of customers buy your products or for what industries?

Essentially we operate in two different manners. On one front, we are doing funded research to create new technologies for both government agencies and industry. In this scenario, we may be working on specific technology for NASA for the Mars Mission or creating a new material for a major oil company to meet specific downhole application needs. On the other front, we actively sell magnesium and other component materials that we manufacture to companies serving the oil and gas exploration industry. These materials have unique properties that make them ideal for creating tools for downhole exploration work.

What are some of the applications of your products? In what ways are they used that readers might be familiar with? What products? How are they used in oil, gas and

TervAlloy dissolving frac ball
TervAlloy dissolving frac ball

defense?

As I noted previously, we literally created a solid-fuel rocket motor, in conjunction with Penn State University. Our most common sales are into more end-use-specific, esoteric applications. As anexample, our TervAlloy magnesium is sold in many cases to companies that build hydraulic fracking plugs. These units are designed to segment horizontal well bores to allow a section to be fracked. Typically, prior practice was that many frac plugs would be set over thousands of feet to allow fracking of multiple stages, and after this process was completed an expensive process of re-drilling the well would have to take place to clear out these frac plugs. Our TervAlloy material actual dissolves after exposure to the environment (elevated temperature and salt water) in these wells; so, the expensive drilling-out process is negated.

How many employees work for the company and in what types of roles? What types of skilled labor do you hire?

Our workforce varies with market demand (e.g., the price of oil), but I’m comfortable saying we operate with 25 or so staff. The skill sets of the organization are broad. We have some truly brilliant material scientists and engineers, along with highly skilled production staff (foundry and machining). We also have the full array of administrative and support people to make this all work.

How long have you been with the company, what is your role and what do you enjoy most about what you do?

I’m a relative newbie here, having joined around one year ago. My role is oversight of our sales and marketing efforts. Our sales efforts are essentially all Terves-focused and international in scope. On the marketing side, I work with both the Powdermet business and the Terves business. For me, the most enjoyable aspect of my role is working in an industry that is new to me – most of my prior experience was in the specialty chemicals and retail consumer markets.

What role does the company play in the manufacturing industry locally? Do you use local suppliers or have local customers?

We absolutely use local suppliers. As I noted earlier, it is one of the reasons we are located here. On the other hand, other than work that we may do for NASA that happens to have oversight at Glenn Research, the vast majority of our customers our outside of the area. This is particularly true for the Terves customers, who are basically located in key oil locations: Texas, the Western U.S., Western Canada, the Middle East, and the North Sea.

In your opinion, what is the biggest challenge that manufacturing currently faces?

In our business, I think there are two areas that represent our greatest challenges. On one front it is innovation – the ability to not only ideate exciting new technologies, but also to quickly move those technologies to production. The other issue is the ability to manage tremendous variability in demand – the oil industry is commodity-driven and very reactive to price movement. Anyone here can tell you on any given day what West Texas Crude is trading for per barrel. The other challenge that we face is that we operate in a true international market, and, essentially, as a raw material supplier, we need to innovate to assure that we can offer differentiation, because there is the inevitable issue of an off-shore producer creating a low-cost knockoff material.

What does the future of manufacturing look like?

From our perspective, it is about people, systems and equipment to produce very high-tolerance components as efficiently as possible.

Who is Bob? What do you enjoy outside of work?

I enjoy Cleveland and spending time with my family and friends. I was raised here, spent time in other locations, and have a great appreciation for our city, our parks, our sports teams and theaters, and the great food venues available to us. I also love the West Side Market.

Euclid Mayor Holzheimer Gail with Terves CEO and COO at ribbon cutting
Euclid Mayor Kirsten Holzheimer Gail with Terves’ CEO and Founder Andy Sherman and COO Brian Doud at Terves’ 20th anniversary event and ribbon-cutting ceremony in August 2016 for the newly opened TervAlloy foundry

Machinery designer and die maker by day, mad scientist the rest of the time

 

restored high school chandelier
Restored chandelier at Cleveland Heights High School

(Courtesy of HGR Customer and Guest Blogger Christopher Palda)

Christopher Palda

How I became an HGR customer

I heard of HGR Industrial Surplus mainly from word of mouth. I used to deal with McKean Machinery where my boss sent me until it was bought by a New York firm and they got rid of the odds and end. As a result, they lost some customers. Many people that buy the little stuff at HGR see the large ticket items and send others they know who need these items. Employees left McKean to start HGR; so, it was a natural transition. You’ll see some of the things I’ve bought at HGR mentioned in the story below.

Recently, my workplace bought a MIG welder at HGR for the construction of Dan T. Moore Company’s plastic extrusion and rolling machine that is the size of a room. It’s for extruding plastic and rolling it into film. What they had at the welding supply store was not what we needed. We required a 100-percent duty cycle machine that could run all day long and found one at HGR.

What I do for work

I’m a die maker and do die repair, hydraulics, welding, machine tool wiring, basically an industrial maintenance technician who handles anything electrical, hydraulic and mechanical. I work for Mahar Spar Industries. A spar is the main strut in a sailboat, and the founder’s name is Mike Mahar. He started out making spars and sailboat masts in his garage in his spare time, and the business evolved from that point. Many ask me the origin of that unique name. I’ve been there for 20 years, and prior to that I was at NASA Glenn Research Center doing composite metallurgy research for jet engine applications and at the same time on a joint project working at Cleveland State University doing metallurgical research in the chemical engineering department where I built the metallurgy lab.

Some of the things I’ve built

One of the items that I am proud of that mostly came from HGR is a hyperbaric chamber. My doctor said that it would be helpful for my health to use one, but medical insurance wouldn’t cover treatments for this off-label use that was proposed; so, I came to HGR and built my own from used air compressor parts for pennies on the dollar. A new one for medical purposes costs $75,000. They usually are purchased by hospitals and medical facilities to treat diabetic patients with wounds that won’t heal, necrotizing fasciitis, carbon monoxide and cyanide poisoning, and scuba diving accidents and are used in clinical studies and trials to increase brain function in people with autism and a few other applications. I am a diver, but luckily haven’t had an accident yet and have not had to use it for that purpose. It cost me about $4,000 to build mine. By dumb luck I found a medical air compressor at HGR normally used in a dental office for the chamber along with a $1,200 medical oxygen regulator for $15 that just needed to be rebuilt. It basically functions as an isolation chamber, and you breathe pure oxygen through a mask as the oxygen regulator increases its output by using the chamber pressure as a reference point.

compressor tank from HGR before it was converted into a hyperbaric chamber
compressor tank from HGR before it was converted into a hyperbaric chamber
hyperbaric chamber side view
outside of completed hyperbaric chamber
inside of handmade hyperbaric chamber made from surplus at HGR Industrial Surplus
inside of finished hyperbaric chamber

 

 

 

 

 

 

 

 

 

 

 

 

 

 

bike trail cutting machine
bike trail cutting machine

We do projects for the Dan T. Moore Company, who also is an HGR customer. Dan believes Cleveland doesn’t have enough bike trails; so, he dropped off a small bulldozer and wanted it converted into a bike trail cutting machine. With our custom attachment it became something that looked like a bulldozer, meat grinder, snow blower hybrid. Some of the hydraulic parts came from HGR. He also wanted to build a steel mill in Bolivia at one point in the past, and we were doing a mockup of the process. We needed a large blower. His people were going everywhere else looking for stuff. I found one at HGR that looked and roared like a jet engine that was 125hp, and it worked great!

bakery oven
bakery oven

Additionally, I do maintenance work at a bakery that has a huge electric oven made in Italy that you can’t get parts for; so, you have to manufacture the parts yourself. Its internal electric flash boiler caramelizes the bread giving it that hard crust by explosively filling the deck with wet steam at the beginning of each bake cycle. The original boiler could not keep up and self-destructed. I copied the basic design with some improvements and made one five times larger. Some of its parts came from HGR.

I also work for Whitney Stained Glass Studio doing artistic metalwork restoration and conservation along with fabricating window frames. Projects include the windows at Stan Hywet Hall and the restoration of the outside stained glass lamps for St. James Catholic Church in Lakewood after a bird built a nest in it. The owner turned it on, and it caught on fire, which melted the solder. I had to strip the patina to fix it, which is considered a no no because it was covered in plastic. I said, “Watch me age this thing 100 years in minutes.” I stuck it in bleach and salt water and put power to it like in a plating operation and totally corroded the thing in 40 minutes.

welder from HGR
TIG welder from HGR

To put the hyperbaric chamber together, I needed to purchase a large TIG stick welder. I found a Miller at HGR for a fraction of the cost of a new one. It didn’t work and needed a little TLC, but if I buy it and it doesn’t work out it’s nice to know I can return it within 30 days. I got it for the cost of the copper scrap, gave it a bath, found a simple control issue and brought it back from the dead. It pulls 105 amps at 240 when I’m welding heavy aluminum. I would turn it on and watch the neighbor’s lights dim. Is the problem 2B solved or not to be? That’s the question. A trip down HGR’s Aisle 2B for some capacitors solved the problem, and the neighbor’s lights didn’t dim anymore. The effect is like pouring a glass of beer. You want the beer but not the foam. These capacitors get rid of the electrical equivalent of the foam.

You know the big speaker in the opening scene of Back to the Future? I said to a friend, “Cool, let’s build one.” A 5-hp stereo system was born! The neighbor would call me for requests when I fired it up in the summer while he was cutting his lawn as long as I played his stuff. The neighbors didn’t like heavy metal, and that’s when the heavy metal station Z Rock was on the air and when I hit the heavy-metal stage in my development.

Building a fire-breathing dragon for the play “Reluctant Dragon” at a children’s theater in 1985 was a blast. When I adapted an old CO2 fire extinguisher and put red lights in the mouth and eyes, it worked first rate. My electronics business in my parent’s basement when I was 10 or 11 aided in paying for this lunacy.

broken chandelier
mangled chandelier prior to restoration

Cleveland Heights High Schools auditorium has huge 300-pound chandeliers. One of them dropped about 35 feet while they were trying to change the light bulbs and smashed into smithereens — a mangled, twisted mess. Redoing all the artistic metal work was a challenge while many others at Whitney Stained Glass restored the stained glass globes.

Near-death experiences

Back in the caveman days, there were only five TV stations. You had to have a movie projector to watch movies. My dad got two 35mm machines from a drive-in that went out of business and modified the optics to work in a house. We had a movie theater in our basement. I was born with mechanical ability, but I learned and worked with my dad who also was handy and was a self-taught mechanical and electrical and hydraulic engineer. He designed tooling and stamping dies along with pollution control in power plants. I could set up and operate these machines as a kid, and when my dad took off the TV back to work on it I saw that there was what looked like a small roll of film inside the that I thought had the Bugs Bunny cartoons on it. He yelled, “Don’t touch that! That is the fly back transformer and has 15,000 volts on it!’

He fixed the TV but left back off. One day, while I was watching it, the picture got odd. I realized the cat was inside. When I went to grab the cat so she would not get hurt, she jumped out and my hands landed on the flyback transformer and lit up blue. Afterward, I felt like lightning had hit me. I woke 15 minutes later across the room and had a revelation — that’s why it’s called a flyback transformer because when you grab one that is what you do!

Christopher Palda as a child working on a car
Christopher Palda as a child working on a car

Another time, as a little kid in the car at the gas station, I asked my mom why the man had a garden hose and was putting water in the car. Mom said it was gas but she wished it was water because it’s cheaper. At home, I put five gallons of water in the car to save mom money after I noticed the spout on the lawn mower gas can fit the end of the garden hose. We ended up stranded the next time we drove it.

I’ve had eight various experiments with electricity. It’s amazing that I’m still alive. I wondered how a vacuum cleaner worked. My dad explained the process of how it worked starting with electrons moving in the cord. I had to find out what an electron looked like; so, I opened up paper clips and was determined to go to the outlet and pull one out. I had two paper clips, one in each side. When they touched, there was a fiery explosion that burned my hands. I got to see a lot of electrons!

My vaporizer broke when I was sick. My dad fixed it by making a new part on his lathe. I saw how it opened up when he took it apart. When everyone was gone, I took it apart while it was plugged in and threw handfuls of salt at it with water to watch the explosions. The power main want “bang” as everything went dark in the house. A voice from downstairs yelled, “Christopher, what did you do now?”