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ABB Survey Identifies Fully Flexible, Connected 'Smart Factories' as Crucial in Transition to Mixed Manufacturing

ABB Robotics’ third Automotive Manufacturing Outlook Survey, in partnership with the leading publication Automotive Manufacturing Solutions, has highlighted how moving to the “Smart Factory” is viewed as a critical next step by global manufacturers and major suppliers.

“Automotive manufacturers are acutely aware that advanced robotics, Artificial Intelligence and digital twinning technology are positive drivers of change,” said Joerg Reger, Managing Director of ABB Robotics Automotive Business Line. "Together, these technologies are forming the building blocks of ‘Smart Factories’ which will help carmakers introduce new models more quickly and cost-effectively, while greatly reducing energy consumption and costs and meeting sustainability targets.”

The benefits of increasing the use of advanced manufacturing technologies, ranging from AI-powered autonomous mobile robots which deliver parts to the line to digital twinning technology, all featured prominently in the latest Manufacturing Outlook Survey.

The survey again highlighted the importance of robotics and advanced automation with 64 percent of respondents agreeing there would be an increase in the use of autonomous mobile robots (AMRs) in automotive manufacturing, while 57 percent agreed that more collaborative robots (cobots) will be introduced alongside workers to perform repetitive assembly tasks.

Respondents cited a major leap for the industry driven by generative AI and software, with 82 percent agreeing that leveraging this technology had the potential to reduce vehicle manufacturing costs, improve quality and streamline the introduction of new models. The adoption of another key technology, digital twinning and simulation, was also expected to rise significantly with 73 percent predicting greater uptake.

The survey also underlined how the uptake of flexible manufacturing was viewed as a crucial way to navigate the complexities many well-known manufacturers face. These include unpredictable levels of demand for certain vehicle types including EVs, hybrids and ICE vehicles, with manufacturers needing to assemble different powertrains on a single site, while maintaining faster product lifecycles. Over the next five years, 84 percent of those surveyed said flexible manufacturing would be a significant factor in vehicle manufacturing.

“Flexible manufacturing is essential when it comes to managing the very real complexities, as well as financial commitments, many carmakers currently need to tackle, and is an approach ABB Robotics has pioneered for our customers,” adds Reger.

“The ability to quickly add extra and different assembly capacity as a module – when customer demand for a particular model suddenly increases or a new powertrain is available – without disrupting production or requiring significant capital expenditure remains vitally important.”

While survey respondents supported the introduction of new technology and viewed the future smart factory positively, there was recognition of some of the challenges involved in reaching this destination. High initial costs (54 percent) were viewed as the biggest constraint while technical challenges (35 percent), cybersecurity and data protection (32 percent) all featured prominently as did workforce adaptation (32 percent) and the lack of skilled employees (28 percent).

“The industry is positive about change and understands in detail which technologies offer the best solutions with autonomous mobile robots, cobots and AI featuring very prominently,” said Daniel Harrison, chief analyst for Automotive Manufacturing Solutions.

“But as we move to automotive smart factories the human factor can’t be ignored, concerns over workforce adaption and a perceived lack of employees skilled in IT were again highlighted by respondents. The industry’s technology partners need to play a major role in training and education as well as unlocking ways to introduce key advances like AI technology in a non-disruptive and accessible way.”

ABB Robotics continues to support the integration of AI with robotics with a particular emphasis on developing natural language programming. In 2024, the company’s AI Start-Up Challenge named T-Robotics and Mbodi as winners. T-Robotics enables natural conversation while maintaining precision; Mbodi’s platform allows robots to learn and adapt to new tasks through spoken language.

Advancements are also being made in autonomous planning capabilities, with VSLAM (visual simultaneous localization and mapping) ABB AMRs equipped with environmental awareness, real-time decision making and semantic differentiation between people and objects. This means they can navigate autonomously in automotive manufacturing environments while performing tasks like tracking stock inventory as they go, sharing this information with other robots, and collaborating safely side-by-side with humans.

For more information, visit www.abb.com or go.abb/robotics.

160th Anniversary of Gleason Corporation

This year marks an important milestone as Gleason Corporation celebrates its 160th anniversary. Founded in 1865 by William Gleason, the company has transformed from a small workshop to a global leader in gear technology, offering comprehensive solutions that encompass design software, manufacturing and metrology equipment, tooling, aftermarket services, and an extensive training program.

Gleason's journey began with the invention of the first bevel gear planer in 1874, a pivotal development that significantly propelled the gear manufacturing industry forward. This innovation was the first of many that established Gleason as a pioneer in gear technology, contributing to many historical technology milestones, Gleason products helped shape the Panama Canal in 1903, invented the Spiral Bevel Gear in 1913, a few years later the hypoid gear, provided transmissions for the famed WWII Sherman tank, Curvic® Couplings and critical geared components for the Apollo space missions, and the highly successful breakthrough technologies like the Phoenix® and Genesis® Machine Series.

Over the years, in addition to organic growth, Gleason has expanded its reach and capabilities through the strategic acquisitions of Hurth Maschinen und Werkzeuge in Munich, the Hermann Pfauter Group in Ludwigsburg, Germany, and adding metrology systems, automation solutions and plastic gears to its product range. These strategic additions have not only expanded its product offerings but also its geographical footprint, establishing manufacturing and service sites in major industrial hubs across the globe, including state-of-the-art factories built in Suzhou, China, and Bangalore, India. In 2017, Gleason acquired Swiss KISSsoft AG, integrating leading gear design and simulation software into its portfolio, becoming the first company in the industry to combine design, manufacturing and metrology elements across virtually all gear types into a Gear Technology Ecosystem.

"We are proud of our rich history and the groundbreaking innovations we have driven in the past 160 years," says John J. Perrotti, Chairman and Chief Executive Officer of Gleason Corporation. "Celebrating 160 years is not just about looking back with pride, but also about looking forward to continuing our commitment to excellence, customer focus, and technological leadership." Gleason continues to advance the industry with high-precision, innovative solutions that meet and exceed the challenging demands of its customers worldwide.

For more information, visit www.gleason.com.

AMT Elects New Board Leadership at February Board of Directors Meeting

AMT – The Association For Manufacturing Technology, which represents U.S.-based providers of manufacturing technology, has elected its 2025-2026 board of directors. Michael Cicco, president and CEO of FANUC Corp., was elected to serve as chairman of the board for AMT.

“I’m both honored and excited to step into my new role with AMT,” said Cicco. “Manufacturers today are facing increasing obstacles that threaten their competitiveness, and AMT is committed to providing innovative solutions that will help our members overcome and find opportunity in those challenges. Alongside a board of esteemed colleagues, I’m proud to help shape AMT’s vision for the future of manufacturing.”

“I am pleased to announce the appointment of Mike Cicco as chairman of the board,” said Douglas K. Woods, president of AMT. “I am eager to work alongside him and the entire board as we continue to strengthen our efforts for AMT members. This is a pivotal moment for manufacturers, with unprecedented support to strengthen the industrial base and economy through both traditional and advanced manufacturing technologies. AMT is committed to leveraging this momentum to drive advocacy for our industry and provide the resources, core products, and services our members need to maintain their competitive edge in the global marketplace.”

In addition to Cicco, Gregory Volovic, president and CEO of Hurco Companies Inc., has been elected to serve as first vice chairman, and Willie Eichele, president of The HEH Group, has been elected to serve as secretary/treasurer. Newly elected to the AMT board for the 2025-2026 term is Markus Stolmar, president and CEO of United Grinding North America Inc.

Daniel D. Janka, president of Mazak Corp. and AMT’s outgoing chairman of the board, will serve ex-officio. In recognition and appreciation for his service to the board, AMT presented Janka with a U.S. flag; it had been flown over the U.S. Capitol in Janka’s honor at the request of Senator Mitch McConnell of Janka’s home state of Kentucky. AMT also presented plaques to outgoing board members Gregory Buck, president of Productivity Inc., for his service as AMT’s treasurer, and Chip Storie, retired machine tool executive.

Also serving on the AMT board in the 2025-2026 term are Blake Consdorf, president and CEO of Bourn & Koch Inc.; Glynn Fletcher, president of EOS North America; Jason Jones, Ph.D., CEO and co-founder of Hybrid Manufacturing Technologies; Melanie Lang, co-founder and CEO of FormAlloy; and Rajas Sukthankar, vice president motion control of Siemens Industry Inc.

For more information, visit AMTonline.org.

The L.S. Starrett Company Announces Key Management Appointments

The L.S. Starrett Co. has appointed four new executives to its global organization, further strengthening its corporate management at the highest levels. Starrett welcomes Roger N. Amrol, Jr. as President and Chief Executive Officer (CEO), Barry D. Laughlin as Chief Operating Officer (COO), Allen E. Look as Global Chief Information Officer (CIO), and Jon-Michael Raymond as Chief Revenue Officer (CRO). The new executives will be based out of Starrett corporate headquarters in Athol, MA, bringing a wealth of manufacturing industry experience, leadership and skills to Starrett as the company focuses on continuous improvement, growth and innovation.

Roger N. Amrol, Jr. succeeds Douglas A. Starrett whose career with Starrett spanned 48 years, as President and CEO. Amrol is poised to lead Starrett forward to a new level, joining the organization after 12 years with Robert Bosch Tool Corporation North America where he was President and CEO for approximately five years. Also, within the Bosch organization, Amrol was President for the SKIL North America brand for four years and led the North America Accessories Business Unit as President for three years. Prior to Bosch, for five years he was with Techtronics Industries as Vice President in procurement, operations, and product divisions. Amrol has a Master of Business Administration from Averett University and a Bachelor of Arts degree from the College of Charleston.

Barry D. Laughlin brings his extensive manufacturing operations experience to Starrett and looks forward to applying his vision and skills to meet the company’s initiatives by implementing day-to-day business strategies and plans. He was most recently COO with Group DEKKO for nine years after being promoted from Executive Vice President of Operations, a position he held for almost two years. Prior to that, Laughlin was in an operations contract role at Caterpillar Inc. for six months. Before that, he was with Navistar for 26 years in various positions increasing in responsibility, with his last position being Director of Global Manufacturing and Custom Products for Navistar, Inc. Laughlin holds a Master of Science in Manufacturing from Kettering University and a Bachelor of Business Administration from Ohio University.

Allen E. Look brings to Starrett over 25 years of information technology experience as Global CIO with skills ranging from business leadership, operational excellence, data analysis and cybersecurity proficiency. Before joining Starrett, Look held global CIO roles for 6 years at privately and publicly held companies including FBG and Hayward Holdings, Inc., and provided interim CIO and executive advisory services in the private equity sector. He has a Bachelor of Science in Computer Information Systems from Thomas College and is an alumni of Crotonville Professional Training and Coaching where he received several certifications.

Jon-Michael Raymond brings vast experience in the industrial market space where he has held sales and finance roles for over 17 years, most recently as Global Sales and Marketing Senior Vice President at FyterTech Nonwovens. Prior to that he was Sales and Marketing General Manager at Mahr after approximately four years with Starrett as its North American Sales and Marketing Director for Industrial Products. For three years before that, he served as Vice President of Sales for PFERD Inc. and preceding that he held various sales and finance positions including with Norton | Saint-Gobain Abrasives. Raymond is a graduate of Worcester State University and Assumption College, where he received a Master of Business Administration.

For more information, visit https://www.starrett.com/.

Fluor Announces Appointment of Breuer as CEO; Constable to Transition to Executive Chairman

Fluor Corporation announced that its Board of Directors has appointed Chief Operating Officer (COO), Jim Breuer, as Chief Executive Officer (CEO), effective May 1, 2025. David E. Constable, Fluor’s current Chairman and CEO, will transition into the role of Executive Chairman on the same date, ensuring continuity of leadership and strategic direction of the company.

Breuer has held the role of COO since 2024, driving a more holistic approach to Fluor’s markets, talent deployment and project delivery excellence. Prior to his COO role, he held several executive leadership positions including Group President of Energy Solutions. His engineering, procurement and construction experience spans four continents in the energy, chemicals, mining and metals, and power sectors. In his 31 years at Fluor, Breuer has held a variety of executive and project roles, including spending half of his career on assignments outside of the United States.

“I am incredibly proud of what we have achieved over the past four years under our ‘building a better future’ strategy, having strengthened our balance sheet, secured a high-quality backlog and restored stakeholder confidence in our project delivery value proposition,” said Constable. “Jim has played an instrumental role in our success and the Board and I have full confidence in his ability to lead Fluor, as we transition from a ‘fix and build’ phase to the next chapter of our strategy, ‘grow and execute’. Jim’s deep knowledge of our global operations, markets, partners and clients will be crucial in driving our heightened focus on business growth, executing projects with excellence, developing the next generation of leaders and delivering sustainable earnings.”

“I am grateful to the Board of Directors for the opportunity to lead Fluor at this pivotal time and to build on the strong platform for growth we have collectively established under David’s leadership,” said Breuer. “I look forward to my ongoing working relationship with David as Executive Chairman, and collaborating with the Board, the Fluor Management Team and our dedicated employees and partners across the globe as we continue to deliver value for our clients and shareholders.”

For more information, visit www.fluor.com.

December 2024 US Cutting Tool Orders Total $179.5 Million, Down 0.6% Year to Date From 2023

Shipments of cutting tools, measured by the Cutting Tool Market Report compiled in a collaboration between AMT – The Association For Manufacturing Technology and the U.S. Cutting Tool Institute (USCTI), totaled $179.5 million in December 2024. Orders decreased 2% from November 2024 and were down 4.3% from December 2023. Shipments totaled $2.43 billion for 2024, down 0.6% from shipments made in 2023. The year-to-date growth rate declined every month in 2024 beginning in April.

“Our industry continued to feel the effects of a stagnated aerospace market as we ended 2024, and this sets us up for a rather uneven first and second quarter,” stated Steve Boyer, president of USCTI. “Cutting tool markets still tended to perform better than other markets through the end of 2024 and start of 2025 but have noticeably softened. Adjusted lower outlooks for this year in the transportation, automotive, aerospace, and defense sectors will project a slower rebound.”

Alan Richter, editor-at-large of Cutting Tool Engineering, added: “With economic and market uncertainties, such as tariffs, supply chains, and inflation, coupled with ongoing and new geopolitical tensions swirling with the election of a new U.S. presidential administration, manufacturers that use cutting tools continued to decrease their tool consumption in December, albeit at a slower rate than November. However, more encouraging reasons for the slide include toolmakers developing cutters that last longer while running at higher machining parameters, productivity gains with automation and AI, and increased efficiency from implementing advanced, or ‘smart,’ technologies.”

The Cutting Tool Market Report is jointly compiled by AMT and USCTI, two trade associations representing the development, production, and distribution of cutting tool technology and products. It provides a monthly statement on U.S. manufacturers’ consumption of the primary consumable in the manufacturing process, the cutting tool. Analysis of cutting tool consumption is a leading indicator of both upturns and downturns in U.S. manufacturing activity, as it is a true measure of actual production levels.

For more information, visit www.amtonline.org.

ECI Software Solutions Appoints Hildebrand CIO

ECI Software Solutions announced the appointment of Brian Hildebrand as chief information officer (CIO). As CIO, Hildebrand will be responsible for developing and implementing ECI's comprehensive IT strategy, overseeing the organization's entire technology infrastructure, and ensuring that ECI’s IT infrastructure remains at the forefront of innovation to address customer needs. 

“Brian has been an instrumental part of our IT and cloud vision over the years, and we’re thrilled to welcome him to this new leadership role,” said Trevor Gruenewald, CEO at ECI Software Solutions. “Brian’s extensive experience in IT leadership, private equity environments, and deep understanding of ECI’s mission uniquely position him to lead our information technology strategy into the future. We’re looking forward to Brian’s innovative ideas for the next chapter in ECI’s technology vision as we look to overcome customer challenges of today and tomorrow.”  

Hildebrand has spent years helping shape ECI’s IT and cloud strategy.  Driving reliability and security for high-availability systems, disaster recovery to ensure customer data remains safe, and integrating acquisitions through scalable cloud operating models. 

"I am deeply honored to step into the role of chief information officer at ECI," said Hildebrand. "Having been part of this incredible organization since 2015, I have gained a profound appreciation for the impactful business management solutions we deliver to small- and medium-sized businesses. As technology continues to evolve, my focus will be on driving innovation, empowering our teams, and ensuring we continue to meet customer needs and exceed the expectations of those we serve." 

For more information, visit www.ECIsolutions.com.

IACMI Names Pokelwaldt Education, Workforce Director  

IACMI – The Composites Institute® – has named Andrew Pokelwaldt as its new director of education and workforce. In this role, Pokelwaldt will lead IACMI's education and workforce team, overseeing strategic planning and the execution of key initiatives and programs to revitalize America's manufacturing workforce.

"Andrew is an excellent addition to the IACMI team," said Chad Duty, IACMI CEO. "Throughout his career, Andrew has been instrumental in shaping manufacturing talent to align with industry needs. His leadership in manufacturing, deep expertise in composites, and extensive experience in workforce training and certification will play a key role in advancing IACMI's mission to developing a highly skilled, advanced manufacturing workforce."

Duty added that IACMI is committed to strengthening the advanced manufacturing workforce by equipping individuals with the skills needed to succeed, broadening access to career pathways, and sparking interest in advanced manufacturing careers to drive continued industry growth.

IACMI cultivates best-in-industry workforce development programs that scale up and connect regional programs to meet the national manufacturing agenda. Supported by the Department of Energy (DOE) and Department of Defense (DOD), IACMI brings together diverse stakeholders and partners in advanced manufacturing. The institute supports training through a wide variety of programs that create accessible pathways to learning and employment opportunities for all workers, including K-12 STEM events, internships, apprenticeships, online and in-person workshops.

Pokelwaldt brings extensive experience to IACMI in workforce development and training, including Composites Instruction Credentials (CCT-I), marine manufacturing, and composites manufacturing technical writing. He previously served as Director of Workforce Training and Credentialing at the American Composites Manufacturing Association (ACMA) and as Training and Development Manager at Brunswick Recreational Boat Group in Knoxville. Most recently, he was the Corporate Technical Training Manager at Newell Brands in Maryville, where he oversaw workforce programs across the U.S., Europe, and Latin America.

Based in Knoxville, Tenn., Pokelwaldt holds a master's degree in education from the University of Tennessee, Knoxville. In addition to his civilian career, he is a former dual-career retired military veteran, having served 20 years in the U.S. Marine Corps and U.S. Army.

For more information, visit https://iacmi.org/.