The term “Symbiotic Simulation” might sound like a science fiction plot point, but in fact, it’s an incredibly useful framework that makes manufacturing processes more efficient by connecting digital tools with real-world facilities. Working with key partners, the Powertrain Manufacturing Engineering group at Ford Motor Company conceptualized and delivered this software solution. And this month, at the Manufacturing Leadership Council’s 2020 ML Awards, the MLC recognized the company’s work in developing it.
What it is: Symbiotic Simulation—or SymSim—is an evolution of discrete event simulation, which is when experts experiment on a computer model representing a facility in order to find improvement opportunities. Usually, that involves manually downloading data, reformatting it and pushing the data into a model ready for optimization.
SymSim shortens that process by making a direct connection to the data that is produced by facilities, pulling data out automatically to help the company understand what’s happening and how its goals can be accomplished more efficiently.
Why it matters: First, connecting the digital model more closely to the physical facility improves the quality of the simulation, which leads to better decisions and results. The second benefit is time. Traditionally, downloading the data, cleaning and processing it would take a week—but the SymSim process can do it almost instantaneously.
The long road: The idea was hatched in 2015, in a Ph.D. project by a member of the company’s PTME group. Once the Ph.D. project ended, the PTME group decided to build it out further, then added a few collaborators: software partner Lanner Group, as well as the University of East London and a team at sustainable manufacturing consultancy HSSMI.
The benefits: In general, the project has helped to improve efficiency and deliver savings by reducing overtime and eliminating costly delays. While Ford just launched the proof of concept in 2019, the project has already saved more than 1,000 hours of engineering time and around $2.7 million. In one Ford plant that was launching a brand-new engine assembly line, the company ran a daily meeting to show—in just 15 minutes—where the bottlenecks had been the day before.
The last word: “Sometimes it’s necessary to revolutionize,” said Ford Simulation & Process Optimization Leader Michael Higgins. “With these technologies, you can get stuck with making incremental changes. Sometimes you need to step back and ask how you can improve processes and leverage technological improvements on a grand scale. That’s exactly what we did.”
Along with many other leaders in manufacturing, Higgins will be one of the speakers at Rethink, the Manufacturing Leadership Council’s virtual summit on navigating disruption and seizing opportunities in the digital era. The summit will take place on October 27 to 29, 2020, and you can register here.
Many people who lost their jobs in the COVID-19 pandemic face a terrifying prospect: that they may not be able to pay for their lifesaving medications. Pharmaceutical manufacturer Eli Lilly and Company recognized that people with diabetes would be worried about affording insulin, so it stepped in to help all those in need—whether or not they have insurance.
The big idea: In April, the company introduced the Lilly Insulin Value Program $35 copay card to help people struggling financially—and while Lilly introduced it as a COVID-19 relief initiative, the company quickly decided to make it an ongoing program. In addition, starting January 2021, people enrolled in participating Medicare Part D plans will be able to access their Lilly insulin for no more than $35 per monthly prescription as part of the Senior Savings Model.
As a result, everyone—whether they have commercial insurance, Medicare Part D or no insurance at all—can opt in to receive their Lilly insulin for $35 per monthly prescription. For those who received the copay card in 2020, they simply need to re-enroll in the program in January 2021. For seniors, it’s important they enroll in a participating Medicare Part D plan during open enrollment (Oct. 15 – Dec. 7, 2020) to ensure they are eligible for this benefit.
A long record of affordability measures: Lilly has always been committed to making sure people get the insulin they need. In 2018, it unveiled the Lilly Diabetes Solution Center—a call center open Monday through Friday from 8:00 a.m. to 8:00 p.m. ET, with live operators fielding questions about insulin affordability and finding solutions for people who don’t know where to turn. The company has been able to drop pharmacy prices for some insulin users and has donated 100,000 insulin KwikPens® to nonprofits. And it is committed to solving even the largest challenges.
“If someone calls and says they’re desperate for insulin and they’re almost out, we’ll find a way to provide them with insulin,” said Lilly Diabetes Communications Senior Advisor Greg Kueterman. “We don’t want people rationing insulin. It’s not good for them, it’s not good for their health, and it’s not good for society.”
A new campaign: To get the message out about Lilly’s new initiative, the company is kicking off a program called “Insulin Affordability: Learn. Act. Share.”—encouraging people to learn about Lilly’s insulin affordability solutions, take action if they need the help and share information with friends and relatives.
The last word: “We want people to know that there’s now a solution out there for everybody,” said Kueterman. “No one needs to pay more than $35 per monthly prescription for their Lilly insulin if they take the right actions.”
You can learn more at insulinaffordability.com or by calling the Lilly Diabetes Solution Center at (1-833) 808-1234.
Manufacturing is a key driver of the American economy—but how does manufacturing in the United States stack up against the rest of the world?
Recently, The Manufacturing Institute and KPMG—a professional services firms providing innovative business solutions and audit, tax, and advisory services—released a new assessment of the cost of doing business in the manufacturing sector for the United States and 16 other major manufacturing exporting nations around the globe.
High costs, but high value: The study found that primary costs (compensation, property, utilities, taxes and interest rates) in the U.S. are on average 16% higher than in the other markets—yet the U.S. ranks fairly high on the list overall at #5.
- Another number bears that out: over the past decade, foreign direct investment in U.S. manufacturing has jumped from $569.3 billion in 2006 to a record $1,785.7 billion in 2019.
The benefits of tax reform: Tax reform made the U.S. a more desirable location for manufacturers, the study found. It compared how the U.S. would have ranked with its pre-reform corporate tax rate of 40% (the combined federal and state tax rate) instead of the post-reform corporate rate of 27%. With the old rate, the U.S. would have ranked only 11th.
The benefits of skilled workers: A major U.S. advantage is its supply of high-skilled workers. According to the study, the U.S. ranks at the top of the list for real value added per employee, along with Ireland and Switzerland. As manufacturing has become increasingly advanced, the need for sophisticated employees keeps growing.
While it’s true that American manufacturing requires more skilled workers, as The Manufacturing Institute has previously shown, the existing workforce is still a big draw due to its productivity.
The bottom line: The United States is an attractive location for manufacturers, despite relatively high costs, because of high worker productivity and the overall business environment.
The last word: “We need to continue to push the envelope of technological innovation and workforce development and recruitment in the manufacturing sector,” said Chad Moutray, chief economist for the National Association of Manufacturers and director of the Center for Manufacturing Research at The Manufacturing Institute. “These efforts will serve to strengthen the sector overall, but also help to maintain the nation’s global competitiveness.”
Last night, the 2020 Manufacturing Leadership Awards Gala recognized some of the most innovative manufacturers in the country, at a virtual event hosted by the NAM’s Manufacturing Leadership Council. The MLC is a global business leadership network dedicated to preparing manufacturers for the opportunities and challenges posed by digitization, automation and technical advancement.
The winners: Presented to individuals and companies in 12 categories, including Sustainability Leadership and Artificial Intelligence and Analytics Leadership, the awards honor world-class manufacturing achievements. You can find the full list of honorees here.
The word from the MLC: “Creativity. Innovation. Excellence. Enlightened leadership. These are the qualities that drive the people of manufacturing to create a better future,” said MLC Co-Founder and Executive Director David Brousell in his opening remarks. “In doing so, they help themselves, their companies and our collective industry improve the quality of life for everyone. . . . All across this country, innovation in manufacturing is on the march.”
Manufacturer of the Year: The MLC honored two manufacturers with Manufacturer of the Year awards: agricultural chemical and seed company Corteva Agriscience, and Humtown Products, which was honored for its work to popularize 3D printing in sand cores. You can check out our profile of Humtown here.
Manufacturing Leader of the Year: This award went to Gerald Johnson, executive vice president, global manufacturing at GM, for his leadership in GM’s pivot to ventilator production in a partnership with Ventec Life Systems, code named Project V.
High Achiever Award Winners: The judges also presented high achiever awards to one winner in each category. Here’s the list:
- Lockheed Martin Corporation in the Artificial Intelligence and Advanced Analytics Leadership category for F-35 Augmented Reality Shop Floor Mobility
- Merck & Co., Inc., in the Collaborative Innovation Leadership category for Digital Fingerprinting
- Humtown Products in the Engineering and Production Technology Leadership category for Commercialization of 3D Printing in the Metal Casting Industry
- IBM in the Enterprise Integration Technology Leadership category for Migrating Supply Chain Quality Workload to Cloud
- Cooley Group in the Industrial Internet of Things Leadership category for Transforming Legacy Machinery into Smart Tech
- Hologic Inc. in the Operational Excellence category for Building a Culture of Operational Excellence
- Starkey Hearing Technologies in the Supply Chain Leadership category for Supply Chain Management Transformation
- The Boeing Company in the Sustainability Leadership category for Diverting Waste to Landfill While Upcycling Excess Airplane Carbon Fiber
- Nexteer Automotive in the Talent Management category for the Manufacturing Engineering Global Talent Management and Training Program
This morning, the leadership of the NAM Board of Directors—Trane Technologies Chairman and CEO and NAM Board Chair Mike Lamach, Dow Chairman and CEO and NAM Board Vice Chair Jim Fitterling, BTE Technologies President and NAM Small and Medium Manufacturers Chair Chuck Wetherington and Protolabs President and CEO and NAM SMM Vice Chair Vicki Holt—released a joint statement to reinforce the industry’s critical role in the fight against COVID-19. The statement reaffirmed manufacturers’ commitment to science and to what’s necessary to plow ahead.
- United in the fight: “As manufacturers for America’s goods and essential products, we have a strong message for our team members and the country. All Americans must do everything in our power to keep our workers, our communities and our fellow citizens safe from COVID-19.”
- Leading by example: “Our industry will continue manufacturing personal protective equipment, medical supplies and therapeutics, racing to develop a safe and effective vaccine and keeping consumer goods and the food supply plentiful. We have been able to do this throughout the pandemic and keep our workers safe because we follow the science.”
- Concluding words: “We all must follow best practices and look out for each other so we can keep the country open, supply the world and defeat this invisible enemy.”
Read the full statement here.
Washington, D.C. – The Board leadership of the National Association of Manufacturers is issuing a call to all Americans to observe COVID-19 safety protocols so manufacturers can continue to work to rebuild the economy. Trane Technologies Chairman and CEO and NAM Board Chair Mike Lamach, Dow Chairman and CEO and NAM Board Vice Chair Jim Fitterling, BTE Technologies President and NAM Small and Medium Manufacturers Chair Chuck Wetherington and Protolabs President and CEO and SMM Vice Chair Vicki Holt released the following joint statement:
“As manufacturers for America’s goods and essential products, we have a strong message for our team members and the country. All Americans must do everything in our power to keep our workers, our communities and our fellow citizens safe from COVID-19.
“Our industry will continue manufacturing personal protective equipment, medical supplies and therapeutics, racing to develop a safe and effective vaccine and keeping consumer goods and the food supply plentiful. We have been able to do this throughout the pandemic and keep our workers safe because we follow the science.
“We will continue to set the right example by practicing the guidance outlined by the CDC and other medical experts. That’s why we encourage all Americans to wear a mask, social distance, avoid large gatherings, use contact tracing and quarantine for 14 days if there is direct exposure to the virus, especially when one is tested positive. We are on the front lines of rebuilding our economy, but we cannot do so until we defeat COVID-19, and we cannot defeat COVID-19 if we fail to protect each other.
“COVID-19 has already taken more than 210,000 American lives, and each week that number grows by the thousands. The economic toll has resulted in millions of jobs lost—some permanently. Among those who survive, many will endure lifelong disabilities. It doesn’t have to be this way. We know the science, and we have the tools. We all must follow best practices and look out for each other so we can keep the country open, supply the world and defeat this invisible enemy.”
The National Association of Manufacturers is the largest manufacturing association in the United States, representing small and large manufacturers in every industrial sector and in all 50 states. Manufacturing employs more than 12.1 million men and women, contributes $2.36 trillion to the U.S. economy annually and has the largest economic multiplier of any major sector and accounts for 63% of private-sector research and development. The NAM is the powerful voice of the manufacturing community and the leading advocate for a policy agenda that helps manufacturers compete in the global economy and create jobs across the United States. For more information about the NAM or to follow us on Twitter and Facebook, please visit www.nam.org.
The CDC updated its guidance on transmission of COVID-19 to clarify that it spreads through airborne transmission, CNBC reports.
What it all means: While the CDC says COVID-19 is still much more likely to be transmitted through respiratory droplets when someone sneezes, coughs, talks or breathes, it’s also possible for smaller particles of the virus to stay in the air for several minutes—or even hours—and spread between people who are more than six feet apart.
Ventilation is key: The new guidance heightens the importance of proper ventilation in fighting the spread of the virus. The CDC clarifies that most airborne transmission happens in poorly ventilated indoor spaces, especially during activities like exercise or singing that might cause people to breathe more heavily.
The recommendation: The CDC is still recommending the same behaviors as before, which include:
- Wear a mask that covers your nose and mouth;
- Social distance by staying at least six feet away from others;
- Wash your hands frequently;
- Clean high-touch surfaces often; and
- Stay home if you feel unwell.
A word from the NAM: “For months, manufacturers have gone above and beyond the recommendations of health officials to protect the health and safety of our nation’s essential workers,” said NAM Director of Labor and Employment Policy Drew Schneider. “Manufacturers are using existing ventilation systems and outdoor air to reduce airborne spread of COVID-19 by increasing air circulation, allowing outdoor air into facilities and using air purifiers. NAM members are still following CDC guidance for social distancing, face coverings and proper hygiene and will continue to retool their facilities in accordance with the recommendations of health experts.”
As concerns grow about another wave of COVID-19 infections this fall and winter, the world has passed a grim milestone: 1 million deaths from COVID-19, The Wall Street Journal (subscription) reports. Here’s the latest on the resurgence of COVID-19 both in the United States and abroad.
- Europe prepares for another wave, sans lockdowns: Cities across Europe are fighting a surge in COVID-19 infections by strengthening social distancing rules—but they aren’t returning to full lockdowns, like those that were put in place this spring, The Wall Street Journal (subscription) reports.
- The numbers for the U.S.: More than 20 U.S. states report COVID-19 spikes over the past week. Meanwhile, an analysis of Johns Hopkins University data found that only 11 states saw cases decline more than 10% in that same time period, The Hill explains. The remaining states reported level infection rates.
- Trouble in the Midwest: Positive COVID-19 test rates have risen above 25% in some Midwest states, an analysis by Reuters found. North Dakota’s positive test rate is averaging 30%, while South Dakota’s has reached 26%. “The World Health Organization considers rates above 5% concerning because it suggests there are more cases in the community that have not yet been uncovered,” Reuters explains.
NAM in action: As the nation prepares for a potential uptick in COVID-19 cases, it becomes even more important to encourage greater adherence to safety practices that limit community spread. A few weeks ago, the NAM launched the “Creators Respond Commitment” to help manufacturing companies encourage wider outside-of-work compliance with safety practices. You can access the email templates to share this campaign with your team members at this link.
The effects of racial inequality can be difficult to quantify. But a new report from Citigroup tries to calculate some of the damage, putting a dollar amount on the economic impact of racial discrimination over the past 20 years, CNBC reports.
This analysis found that racial inequality and discrimination reduced U.S. GDP by more than $16 trillion over that time period. That total includes money that Black Americans lost due to inequalities in salary, housing, access to higher education and lending to business owners.
Here’s what manufacturers are doing to address racial inequality in the industry:
- Pledge for Action: In June, the NAM’s Executive Committee unanimously passed an 11-point commitment plan for manufacturers to advance justice, equality and opportunity for Black people and all people of color.
- Closing the opportunity gap: Last week, during the NAM board meeting, manufacturers committed to taking 50,000 tangible actions to increase equity and pay in the industry, as well as creating 300,000 pathways to job opportunities for Black people and all people of color. As a result, manufacturing will reflect the diversity of the overall U.S. workforce by 2030.
Washington, D.C. – Following the industry’s June “Pledge for Action,” the National Association of Manufacturers brought industry leaders together to focus on recommending bold next steps manufacturers can take to increase equity and parity for underrepresented communities in America.
The Task Force on Closing the Opportunity Gap has put forth actions that will transform the industry workforce: By 2025, manufacturers commit to taking 50,000 tangible actions to increase equity and parity for underrepresented communities, creating 300,000 pathways to job opportunities for Black people and all people of color. In doing so, manufacturing will reflect the diversity of the overall U.S. workforce by 2030.
The Manufacturing Institute, the NAM’s workforce development and education partner, will collect individual commitments from companies to ensure that the goal of 50,000 actions is met by 2025 and that the industry reaches its diversity goals by 2030. NAM President and CEO Jay Timmons affirmed the commitment on behalf of the industry.
Timmons, Trane Technologies Chairman and CEO and NAM Board Chair Mike Lamach and Manufacturing Institute Executive Director Carolyn Lee made the following statements on this landmark initiative.
“Our industry plays an integral role in lifting up people and communities,” said Lamach, “and now we have a special obligation to stand with and support all people who face injustice. We must play a part in tearing down the persistent and pernicious structural barriers to opportunity in this country.”
“I am proud to make this commitment on behalf of the industry and thank Mike and the task force for their leadership. As manufacturers across America redouble our efforts to build more inclusive and equitable workplaces and communities, we will be the catalyst for even greater change,” said Timmons. “We can spark a chain reaction for equity—that makes our businesses more successful, our communities stronger and our nation one that truly guarantees ‘liberty and justice for all.’”
“Not only are manufacturers making a bold promise, but they are also committing to be held accountable,” said Lee. “The Manufacturing Institute will collect individual commitments from companies, support their efforts with key resources and track the industry’s progress in creating these opportunities and pathways over the coming years to ensure we reach our 2030 target.”
Background on the Task Force: On June 11, the NAM’s Executive Committee unanimously approved the 11-point “Pledge for Action” to advance justice, equality and opportunity for Black people and all people of color. The Task Force on Closing the Opportunity Gap’s commitment, announced today, follows through on elements of the “Pledge for Action.”
Members of the task force include the following:
- Task Force Chair: Mike Lamach, chairman and CEO, Trane Technologies and NAM Board chair
- Dev Ahuja, SVP and CFO, Novelis Inc.
- Alejandro Alvarez, SVP, chief production officer and sustainability officer, Brown-Forman Corporation
- Neil Chapman, senior vice president, Exxon Mobil Corporation
- Julie Copeland, CEO, Arbill
- Mark Cordova, president, Centennial Bolt, Inc.
- Chris Edwards, Co-CEO, Edward Marc Brands, Inc.
- Jim Fitterling, chairman and CEO, Dow Inc. and NAM Board vice chair
- Vicki Holt, president and CEO, Protolabs and NAM Small and Medium Manufacturers Group vice chair
- Frederick Humphries, corporate VP, U.S. government affairs, Microsoft Corporation
- Vimal Kapur, president and CEO, Honeywell Building Technologies
- Lawrence Kurzius, chairman, president and CEO, McCormick & Company, Inc.
- Mike McDermott, president, Pfizer global supply, Pfizer, Inc.
- Aneesa Muthana, president and CEO, Pioneer Service Inc.
- Chris Nielsen, EVP – product support and chief quality officer, Toyota Motor North America
- Quentin Roach, SVP – global supply chain and chief procurement officer, Mondelez International
- Kathy Wengel, EVP, chief global supply chain officer, Johnson & Johnson
- Chris Womack, president, external affairs, Southern Company
The National Association of Manufacturers is the largest manufacturing association in the United States, representing small and large manufacturers in every industrial sector and in all 50 states. Manufacturing employs more than 12.1 million men and women, contributes $2.36 trillion to the U.S. economy annually and has the largest economic multiplier of any major sector and accounts for 63% of private-sector research and development. The NAM is the powerful voice of the manufacturing community and the leading advocate for a policy agenda that helps manufacturers compete in the global economy and create jobs across the United States. For more information about the NAM or to follow us on Twitter and Facebook, please visit www.nam.org