The manufacturing sector faces a significant challenge: a looming skills gap that could have dire consequences for the industry. According to research from Deloitte and The Manufacturing Institute, the US manufacturing sector might encounter a shortfall of 2.1 million skilled workers by 2030.
Here Pontus Westlin, product manager metal cutting tools and manufacturing solutions, Sandvik Coromant, explains how advanced turning technologies can pave the way for a more efficient and resilient industry.
The shortage of skilled workers is a critical issue affecting manufacturing across the globe. Indeed, Deloitte reports this gap could potentially cost global industry $1 trillion in lost revenue in 2030 alone. The situation is compounded by the constant need for manufacturers to enhance productivity and efficiency.
As experienced workers retire and fewer young professionals enter the field, the industry is struggling to find personnel with the necessary expertise to operate complex machinery and carry out intricate tasks. This gap in skills not only threatens the ability of manufacturers to meet production targets but also undermines the overall efficiency and quality of manufacturing processes.
Moreover, the rapid pace of technological advancement in manufacturing further exacerbates the problem. New technologies and processes require specialised skills and training, but the available workforce is often not sufficiently equipped to handle these advancements. As a result, manufacturers face the dual challenge of keeping up with technological progress while managing a workforce that is increasingly difficult to train and retain.
The pressure to improve productivity
In addition to the workforce shortage, manufacturers are under immense pressure to continuously improve productivity and efficiency. This pressure comes from various sources, including global competition, market demands for higher quality products, and the need to maximise return on investment. Companies are compelled to adopt more efficient processes and technologies to stay competitive and meet the ever-increasing expectations of their customers.
Improving productivity often involves implementing new technologies and streamlining operations, which can be challenging when faced with a shortage of skilled workers. The need for more efficient manufacturing processes becomes even more urgent as companies strive to balance the demands of quality, cost and speed with the limitations imposed by their available workforce.
The role of automation and advanced technologies
To address these challenges, many manufacturers are turning to automation and advanced technologies as a solution. Automation can help reduce the reliance on manual labour and mitigate the impact of the skills gap. However, the successful implementation of automation and advanced technologies requires careful planning and integration to ensure it delivers the desired improvements in productivity and efficiency.
Advanced turning technologies, in particular, offer a promising avenue for overcoming these challenges. By simplifying complex operations and enhancing automation, these technologies can help manufacturers achieve higher output and efficiency with a reduced dependency on highly skilled labour. As we explore these solutions further, it becomes clear that advanced turning technologies have the potential to bridge the skills gap and drive significant improvements in manufacturing productivity.
Addressing the skills gap with advanced turning technologies
To overcome these obstacles, innovative solutions are required. Sandvik Coromant’s PrimeTurning™ process offers a promising answer, transforming traditional turning operations to address these challenges head-on.
PrimeTurning is a cutting-edge turning method developed by Sandvik Coromant that allows for turning in all directions. This versatile process simplifies complex operations and significantly enhances automation, reducing the dependence on highly skilled labour — enabling workers to achieve higher output with greater ease.
The key to PrimeTurning lies in its unique approach to turning. By machining with a small entry angle, the method not only ensures high productivity but also extends tool life. This technique allows manufacturers to perform turning operations with enhanced efficiency compared with conventional methods. The results speak for themselves: increased productivity and longer-lasting tools are just some of the benefits experienced by users.
Optimised tools for superior performance
To unlock the full potential of PrimeTurning, specialised tooling is essential. Conventional tools fall short in terms of chip control and clearance angles, making them unsuitable for PrimeTurning™ operations. In response, Sandvik Coromant has developed CoroTurn® PrimeTurning™ tools.
A machining company in Brazil achieved significant productivity and tool life improvements when turning cast steel (SAE/AISI 1045) hubs on a Gildemeister CTV 250 CNC turning centre by adopting CoroTurn Prime A-type inserts. By maintaining the same cutting speed as the previous insert (300 metres per minute), it was able to increase feed rates from 0.25 millimetres per revolution (mm/r) to 0.4 mm/r and the depth of cut from 1.5 mm to 3 mm. This resulted in a 59% productivity increase and 55% longer tool life, significantly impacting profitability, especially with an annual production of over 120,000 hubs.
The latest advancements in the series are the CoroTurn Prime B-type inserts. These next-generation tools feature double-sided negative inserts with four cutting edges. This design not only enhances cost-efficiency but also improves robustness and chip control. The updated geometries and tip seat design allow for deeper cuts, higher machining speeds, and better performance with tough materials like high-strength steels.
One of the standout features of the CoroTurn Prime B-type insert is its improved heat and load distribution. Unlike conventional inserts, which concentrate stress at the corners, these new inserts distribute heat and load across four cutting edges. This design ensures better tool life and stability, even under higher axial depths of cut and cutting speeds.
Enhancing productivity with digital solutions
To further amplify the advantages of PrimeTurning, Sandvik Coromant has integrated CoroPlus® Tool Path digital software. This online tool path generator provides precise programming codes and setup techniques, ensuring optimal parameters for each machining application. When combined with CoroTurn Prime cutting tools, the result is efficient edge use, minimised chip jamming and overall improved machining performance.
CoroPlus Tool Path also supports seamless integration with leading CAM software packages, such as Mastercam, TopSolid, Siemens NX, CAMWorks, and GibbsCAM. For shops without CAM software, CoroPlus Tool Path serves as a standalone solution for generating NC codes, ensuring that all manufacturers can benefit from advanced turning technologies.
Driving manufacturing wellness
Sandvik Coromant’s commitment to advancing manufacturing extends beyond tool technology. The company’s Manufacturing Wellness initiative emphasises the integration of smart software and precise tool data to enhance production accuracy and efficiency. By leveraging digital technologies, manufacturers can ensure accurate data flow from CAD to delivery, unlocking significant productivity gains and navigating the path to a digitally driven future.
While the manufacturing sector faces a critical skills gap, advanced turning technologies like PrimeTurning™ and digital solutions such as CoroPlus Tool Path offer viable pathways to overcoming these challenges. By adopting these innovations, manufacturers can improve productivity, reduce reliance on highly skilled labour, and pave the way for a more efficient and resilient industry.
For more insights into how machine tool solutions can optimise costs and enhance efficiency, explore Sandvik Coromant’s website.
