Archive for September, 2015

SME Education Foundation Works to Grow Next Generation of Manufacturing Workers

Wednesday, September 30th, 2015

The 2015 ManpowerGroup annual Talent Shortage Survey reveals that 32% or 1 in 3 of “U.S. employers report difficulties filling job vacancies due to talent shortages,” down 8% from 40% in 2014. This 10th survey shows that “skilled trades remain the hardest to fill for six consecutive years.” Among U.S. employers, 48% acknowledge that talent shortages have a medium to high impact on their business, but few are putting talent strategies in place to address the problem…despite the negative impact on their business.”

One reason for the shortage is that public misperceptions of advanced manufacturing has led young people entering the workforce to choose other career paths. In an article titled, “What the shortage in skilled manufacturing workers means to a hungry industry” of the e-newsletter Smart Business, Kika Young, human resources director at Forest City Gear Co. Inc. of Rockford, IL, said “Most people in Gen Y out of high school don’t think of manufacturing as a career or as a good option. They don’t think of it as glamorous; they think of it as dark and dingy and dirty and aren’t interested in going into that.”

If we want to attract today’s youth to manufacturing careers, we need to change their perceptions about what the manufacturing industry is like and show them what great career opportunities exist in the industry. We need to expose them to the variety of career opportunities in manufacturing and help them realize that manufacturing careers pay 25-50 percent higher than non-manufacturing jobs, so they will choose to be part of modern manufacturing. The spotlight needs to be on the high-tech environment of modern manufacturing. New technologies such as 3D printing, robotics, and advanced analytics underscore the reality that a career in manufacturing does not entail working in a dirty, dangerous place that requires no skills.

SME Education Foundation is working to change the image of manufacturing and prepare youth for careers in advanced manufacturing through its Partnership Response In Manufacturing Education (PRIME®) initiative.

PRIME® is a collaborative model that engages regional manufacturers, local schools and other community representatives to establish a tailored advanced manufacturing / STEM education that provides high school students with relevant, hands-on knowledge and skills. PRIME® gives manufacturers a voice in education, builds student awareness of manufacturing career pathways, and provides youth with 21st century manufacturing skills, which can lead to industry credentials. Students graduating from the PRIME® program are often capable of successfully transitioning to the manufacturing workforce immediately upon high school graduation.

Established in 2011, PRIME® has grown to 36 schools in 21 states, impacting more than 6,500 students annually with 70 percent of graduating PRIME® seniors pursuing a post secondary education in manufacturing or engineering. SME Education Foundation has also supported 144 PRIME® students with nearly $400,000 in scholarship awards.

In my home state of California, there are six PRIME® schools: Esperanza High School, Hawthorne High School, John Glenn High School, Petaluma High School, Rocklin High School, and San Pasqual High School.

SME Education Foundation is working to expand its network by working with corporate partners to sponsor the development of new PRIME® sites at high schools throughout the country. “PRIME® is forging a path to revitalize manufacturing education and fostering the development of a highly skilled, STEM-capable workforce,” said Brian Glowiak, director of the SME Education Foundation. “Through the support of visionary corporate partners, like Alcoa and Honda, we are helping to create the next generation of manufacturing engineers and technologists and championing one of the most critical elements for innovation success.”

SME Education Foundation and PRIME® provide a winning solution for students by offering them opportunities to:

  • Collaborate with local SME Chapters and industry partners to co-host events
  • Engage with other students and educators in the PRIME® network to share their experiences and creative lesson plans as well as participate in student competitions
  • Participate in Advanced Manufacturing/STEM camps with younger students and other extracurricular activities
  • Receive post-secondary educational scholarships
  • Engage with SME members who can share their technical knowledge and experience by mentoring PRIME students, offering internships and providing job-shadowing opportunities.
  • Attend student summits at SME’s national manufacturing events. These summits allow students, parents and educators to interact face-to-face with representatives of companies that provide revolutionary technologies and business-changing innovations.
  • Implement training materials and curriculum from Tooling U-SME, the industry leader in manufacturing learning and development.
  • Receive SME’s Advanced Manufacturing Media, which produces digital and print publications that cover relevant manufacturing news, technology and advances.

PRIME® Success Story:

In 2014, Denbigh Aviation Academy in Newport News, Virginia was selected for PRIME® designation through the SME Education Foundation.Students at the Aviation Academy, are building a full-sized, 750-pound, two-seat aircraft. At the culmination of the project, they are planning to take this student-built aircraft to the skies! The Aviation Academy is a four-year, high school program in Newport News Public Schools, located behind the Newport News-Williamsburg International Airport. Learners focus on careers in aviation, electronics, engineering and technology. “We are able to get real world experience and it ties in with aerospace manufacturing /engineering. It’s a good thing because the fields are lucrative and growing,” says Laura Prox, a junior at the Denbigh Aviation Academy.

As one of the first sites on the East Coast to partner with Eagle’s Nest Projects (an organization that donates the plane kits to schools to build these aircrafts), students can immerse themselves into the manufacturing and aviation sector. An elite team of 30 students have completed the fuselage and tail sections. These students demonstrate an authentic example of manufacturing brought to life in the classroom. Students are assigned roles from management to labor based upon their coursework and experience. They are learning and employing fastening systems and procedures that can be found at any aviation assembly facility. Using the materials, reading the blueprints and drawings, and understanding principles in assembly outline some of the talents students gain. Throughout the process, some of the “soft skills” also emerge such as teamwork, communication and problem solving.”

Manufacturing Day 2015 will occur on Friday, Oct. 2, and throughout the month of October, SME will be supporting Manufacturing Day through chapter activities and events, the SME Education Foundation’s PRIME® school network and Tooling U-SME. Here’s what PRIME® schools are doing for Manufacturing Day!

PRIME® exposes our youth to the modern manufacturing environment and changes the image of manufacturing to one that is “cool” and full of exciting career opportunities for our youth. This will enable us to recruit the next generation of manufacturing workers to fill the skilled worker positions now going unfilled.

The question is: Will you be the corporate executive who joins the PRIME® program to sponsor more schools to expand the program to hundreds of schools in all 50 states? If so, go to this link. Or, will you be the corporate executive that will have to admit to his children or grandchildren that you are partly responsible for reducing their career opportunities for good paying jobs in manufacturing because you offshored manufacturing and/or imported foreign workers to replace American workers at your U. S. plant?

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Why are there so few states with “Bottle Bill” laws?

Tuesday, September 22nd, 2015

American consumers have increasingly favored recycling to benefit their community and the environment. Recycling is defined as the process of collecting and processing materials that would otherwise be thrown away as trash and turning them into new products. One of the best ways to promote recycling is with “bottle bills,” which is another way of saying “container deposit laws.” A container deposit law requires a minimum refundable deposit on beer, soft drink and other beverage containers in order to ensure a high rate of recycling or reuse. After learning that only ten states have container deposit laws, I decided to investigate why this is the case.

I am sure that everyone would agree with the following benefits of recycling cited by the Environment Protection Agency’s website:

  • Reduces the amount of waste sent to landfills and incinerators;
  • Conserves natural resources such as timber, water, and minerals;
  • Prevents pollution by reducing the need to collect new raw materials;
  • Saves energy;
  • Helps create new well-paying jobs in the recycling and manufacturing industries in the United States.

The three steps to recycling materials listed on the website seem simple:

  • Step 1: Collection and Processing – Recyclables are collected by curbside collection, drop-off centers, and deposit or refund programs. Next, “recyclables are sent to a recovery facility to be sorted, cleaned, and processed into materials that can be used in manufacturing. Recyclables are bought and sold just like raw materials would be, and prices go up and down depending on supply and demand in the United States and the world.”

The one hitch in these steps is that it takes enough recyclable material to make it profitable to manufacture products out of recycled material or make new products that utilize recycled content, such as carpeting, park benches, and even asphalt. The question is do we have enough recycled material to make the clear water bottles that could be endlessly recycled?

When you think of all of the trillions of clear water bottles purchased in the U. S. by American consumers, you would think that there would be more than enough material to keep making water bottles out of recycled material without having to use any virgin material. However, since there are only 10 states with bottle deposit laws, this is not the case. These states are: California, Connecticut, Hawaii, Iowa, Maine, Massachusetts, Michigan, New York, Oregon, and Vermont. Oregon was the first state to successfully pass a bottle deposit law in 1971, Vermont was the second state to pass a bottle deposit law in 1973, and Hawaii was the most recent in 2002. Most of the other states passed laws in the 1980s. Delaware passed a law in 1982, but it was repealed in 2009. The deposit is 5 cents for every state except Michigan, where it is 10 cents.

Tennessee proposed a bottle bill in 2009 and 2010 that failed to pass even though ten county commissions voted to endorse the bill. It would have required a five-cent deposit on beverage containers. The recycling rate in Tennessee is 10 percent, which was projected to increase to 80 percent with a bottle bill. Discarded bottles and cans are the primary contributor to litter in Tennessee.

Texas attempted to introduce a bottle bill (SB 635) into legislation in 2011, but lost by a vote of 101 to 40. It would have required a ten-cent deposit on beverage containers under 24 fl. oz. and 15 cents for larger containers. Recycling promoters filled a new bill in 2013, SB 645, but it was left pending in subcommittee on 4/22/2013. Two new bills have been introduced in Texas in the 2015 legislative cycle ? HB 2425 Regarding Refundable Deposits and SB 1450 Calling for Refundable Deposits.

Why is there so much opposition to bottle bills?

According to the Institute, “Bottle bill opponents include beverage container manufacturers, soft drink bottlers, beer, wine and liquor distributors and retail grocers. As ‘new age’ drink containers are targeted for inclusion in existing bottle bills, juice, sports drink and bottled water manufacturers have joined the anti-bottle bill forces…”

Major opponents of bottle bills are:

  • Anheuser Busch
  • The Coca Cola Company
  • Pepsi-Cola Company
  • Can Manufacturers Institute
  • Distilled Spirits Council of the United States
  • Food Marketing Institute
  • International Bottled Water Association
  • National Beer Wholesalers Association
  • Grocery Manufacturers Association
  • National Food Processors Association
  • National Grocers Association
  • American Beverage Association

The Container Recycling Institute claims that these companies and organizations have spent huge sums of money “to defeat ballot initiatives over the past twenty years, with industry opponents outspending proponents by as much as 30:1.”

During the last three years the three leading container trade groups (Aluminum Association, the Glass Packaging Institute, and the Association of Postconsumer Plastic Recyclers) have changed their position and now support bottle bills because of the success of existing bottle bills.

What are the reasons given for opposing bottle bills? The Container Recycling Institute lists the following reasons on a page titled Myths and Facts:

  • Deposits aren’t needed where there is curbside recycling.
  • Deposit systems target only a small part of the waste stream (less than 3% of municipal solid waste (MSW) by weight).
  • Deposit systems address a small portion of litter: 7 to 25 percent.
  • Deposit return is inconvenient (consumers prefer home curbside bins).
  • Deposits rob curbside programs of valuable aluminum can revenue.
  • Deposits are more expensive than other recycling programs.
  • Deposit returns are expensive for distributors.
  • Deposits are a tax” and increase the price of beverages.

I live in California, which is one of the bottle bill states, and we also have curbside recycling in the city of San Diego. I prefer to separate out the containers for which I paid a deposit and take them to a recycling center to get my deposit money back. In the major cities of California, stores do not take the bottles back. You can take them to recycling centers conveniently located in the parking lots of neighborhood shopping centers or to municipal waste management landfills where privately owned recycling centers are located.

I do not understand how anyone could consider a deposit fee a “tax” because it is refunded. None of the sales taxes I pay are ever refunded to me. Also, under container deposit systems, the cost of recycling is borne by producers and consumers, not by government and taxpayers as is the case for curbside recycling programs.

The Container Recycling Institute says that beverage containers comprise 40-60% of litter. Because of the bottle deposit law in California, you rarely see any bottles as litter. Homeless and poor people pick up all of the bottles that could be litter on streets and sidewalks to turn them in to get the deposit money. States that have bottle bills “showed reductions in beverage container litter ranging from 69% to 84%.”

In January 2015, a report was released, “Waste and Opportunity 2015: Environmental Progress and Challenges in Food, Beverage, and Consumer Goods Packaging” by Conrad B. MacKerron, Senior Vice President of As You Sow, a nonprofit organization dedicated to increasing environmental and social corporate responsibility. The Project Editor was Darby Hoover, Senior Resource Specialist of The Natural Resources Defense Council (NRDC), an international nonprofit environmental organization with more than 1.4 million members and online activists.

The report revealed that “With an overall recycling rate of 34.5 percent and an estimated packaging recycling rate of 51 percent, the United States lags behind many other developed countries.” With regard to beverage recycling, the report states, “Major beverage companies like Coca-Cola, Nestlé Waters NA, and PepsiCo are taking positive individual actions to boost bottle and can recycling. Still, most brands support neither a container deposit nor an EPR (extended producer responsibility) scheme to boost recycling—two proven ways to increase container recycling.”

With regard to beverage containers, PET (Polyethylene terephthalate) is the material most frequently used and thus is “currently the most recycled plastic material, yet only 30 percent of PET bottles are recycled. But since 94 percent of the U.S. population has access to PET collection, there is much more PET that could be recovered. “High demand and limited supply for recycled PET (rPET) demonstrates the economic potential of increasing recycling rates if materials can be recovered without significant contamination.” However, “U.S. reclaimers reported average yield losses of 31 percent for PET bales from curbside programs and 25 percent for bales from deposit programs” due to contamination by other recycled materials.” The report recommended expanding the use of PET to other types of packaging such as clamshell food containers to increase the supply of rPET.

One good reason to expand container deposit laws is stated in the report: “Recycling also helps create new, well-paying jobs in the recycling and manufacturing industries. The firms that process metals, paper, electronics, rubber, plastic, glass, and textiles represent 137,000 direct jobs and $32 billion in revenue. When suppliers and indirect impact are factored in, the industry supports nearly half a million jobs and generates a total of $90 billion annually in economic activity. If we increased the U.S. national recycling rate to 75 percent by 2030, we would generate nearly 1.5 million new jobs.”

Other key findings of the report were:

  • Up to 50% of the U.S. population may lack convenient access to curbside recycling for commonly recycled materials like bottles, cans, and newspapers.
  • Companies are required to pay for collection of materials in Europe, Canada, and other markets, but fight accepting that responsibility in the U.S.
  • Many companies also fight container deposit legislation – the most successfully demonstrated method to increase recycling rates, yet only operating in 10 states.

I agree with one of the recommendations of the report: “Increasing our ability to recycle packaging successfully will lead us closer to developing a circular economy in which raw materials are captured and processed to re-enter commerce many times over, thus increasing resource efficiency and reducing greenhouse gas emissions and our reliance on nonrenewable natural resources.”

Since clear PET plastic bottles can be recycled nearly endlessly, one of the best ways to accomplish this is to pass bottle bills in more states in the U. S., so we can increase the domestic supply of recycled PET. We also need to pass legislation to keep recyclers from selling the PET containers to China so that American companies like Plastic Technologies Inc. won’t have to buy recycled PET from other countries.

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Entrepreneurial Spirit Molds Success of Plastic Technologies Inc.

Tuesday, September 22nd, 2015

During my tour of manufacturing plants in the Toledo, Ohio region last month, I decided to write an article about Plastic Technologies, Inc because of the interesting story about Dr. Tom Brady who founded the company in 1985. When I interviewed Dr. Brady last week, he told me that when he worked for Owens-Illinois, Inc. from 1971-1984, he had become the VP and Director of Technology and had led the development of the first PET (polyester) plastic soft drink container and had directed the technical activities for all of O-I’s plastic product lines.

When I asked him what led him to start PTI, he said, “In late 1985, I happened upon a unique opportunity to start the company. Several of the major Coca-Cola bottlers were seeking to expand their already successful PET bottle manufacturing operations and to develop new and innovative PET plastic soft drink packaging products. The four largest Coca-Cola regional bottling cooperatives agreed to jointly sponsor and fund product development and engineering projects, and they approached me to manage those project development efforts. Not having an interest in just changing jobs, I made a counter offer to those Coca-Cola cooperatives to establish a separate independent company for the purpose of managing their projects. When they agreed, I left O-I to start Plastic Technologies, Inc. and signed long term contracts with all four Coca-Cola cooperatives.”

Dr. Brady also said, “Because of my industry experience, I was quickly able to identify additional customers that were non-competitive to Coca-Cola and I hired a small, but highly experienced professional staff, to do the technical development for the Coca-Cola Cooperatives and for other customers. Because of our professionalism and experience, we were quickly able to establish a reputation in the industry as a high quality PET R&D and technical support company. As our technical staff expanded and our revenue grew at compound annual rates of 35%, we moved to a larger facility in 1989 and set up both analytical testing and process development laboratories, with the capability of prototyping and testing PET containers and preforms. We founded Phoenix Technologies International LLC in 1991 in nearby Bowling Green, Ohio and have since then expanded the plant three times to produce recycled PET using proprietary technology.

Because PET had become the material of choice for new packaging during the 80’s and 90’s, we were able to quickly expand our customer base and to become involved in developing many different products and businesses, including health care packaging, plastic recycling, specialty compound development, and even leisure products. Our experiences outside the PET packaging field provided a basis for us to hire additional technical professionals to staff our laboratories and establish a reputation in the plastics industry as a substantial technical development company.

Since those early days, we have developed relationships with most major manufacturers, resin suppliers, machinery builders, brand owners, and converters. Today, we even supply preforms for blow molding to customers needing specific quantities or unusual designs. We have also learned how to work effectively with competitive customers andwe have become recognized for our excellence in protecting customer intellectual property and confidentiality. Today, our customers are involved in every step of the PET value chain from raw material supply through end of life recyclability.”

I asked if they were affected by the Recession of 2008-2009 and if so, what did they do to survive it? Dr. Brady said, “The recession did have a big effect on PTI’s business, but the recession, per se, was not the most significant issue. Rather, the recession just added to the challenge of changes that were already happening in the world at large. As is true for almost every business today, one of the challenges for PTI today is to redefine its business going forward. Dr. Brady said that what PTI has done successfully for 30 years is no longer as different and special as it once was. The challenge for PTI, and for every business today, is to find the “gaps” in the markets of the future that can be filled by employing the experience and knowledge that has been developed over many years.

Mr. Brady did say that “we had to do some things differently during the recession. We had to get more professional about sales because there are many more companies selling the same technologies and services now. The biggest impediment to our continued growth is that there are more competitors, so that staying ahead of the competition is a bigger challenge.” When he started the company, he was working with the top levels of management at his major customers. Now, he says that business is being done at a different level. More business is handled today by professional purchasing agents, so you have to be more price competitive than in the past. They also went through formal training in Lean, which has been beneficial to their manufacturing businesses, because, he says, “You have to be more efficient to be competitive in every aspect of your business today.” However, the Lean initiative didn’t affect PTI’s testing lab. Rather, becoming ISO certified has had more of an impact on that lab.”

Since I had seen a whole wall of patents PTI had been granted on display at their headquarters, I asked if the change in patent law under the America Invents Act of 2011 affected his company. He replied, “We have to take the steps to be “first to file” instead of being able to rely on being “first to invent.” We have to file more provisional patents than we ever had to in the past, which adds another big burden and costs that we didn’t have previously. Our number of patent applications has shrunk now that we can’t depend on being first to invent. Anything that adds bureaucratic activity becomes a burden on business.”

After my visit, I had emailed Dr. Brady information on the proposed patent legislation (H.R. 9 and S.1137) and asked if these bills would have an effect on his company.” He responded, “You don’t have time to fight everything that comes up. You try to work around it. In fact, we find that patents are less valuable than they used to be. It is more important to be first to the market and to be innovative. Our growth hasn’t been about becoming a bigger and bigger company. We started Phoenix Technologies and our other companies so that those teams could be more entrepreneurial themselves. Our growth model has been to expand by creating our own “Intrapreneurs,” by offering those intrapreneurs ownership and by growing as a family of companies. Our PTI family of companies now includes two manufacturing companies, two technical development and engineering service companies and three joint venture companies that license technology or sell specialty services to the packaging industry (Preform Technologies LLC, Phoenix Technologies International LLC, PTI Europe SARL, PETWall LLC, Minus 9 Plastics LLC and The Packaging Conference). Today, many PTI employees are owners and are in a position where they can truly feel it’s their company. Any employee can be considered by the management team for an opportunity to buy an equity stake, and 40% of PTI employees are owners today. We have more than 200 employees worldwide and many of the products you buy every day are sold in plastic containers designed by one of our companies.”

During my visit, I was astonished to learn that there are only 11 states that have bottle deposit programs to encourage recycling ? California, Connecticut, Delaware, Hawaii, Iowa, Maine, Massachusetts, Michigan, New York, Oregon, and Vermont. In these states, about 80% of bottles are recycled, while in non bottle-deposit states only about 20% of bottles are recycled. I asked why more states didn’t have bottle deposit programs, and Dr. Brady responded that many major companies oppose the programs because they say it would add to their costs. Dr. Brady explained, “You have to have an infrastructure in place to get enough material to make recycling profitable. However, he emphasized that everybody, even those who think deposit systems cost more money, would win if there was more recycled material, because the costs for virgin material would go down. He also pointed out that a lot of the recycled material goes offshore to China and other Asian countries because it is cheaper to ship the material in the empty containers that are going back to Asia than it is to ship the material to Ohio. We are a big enough company that we can buy recycled material from other sources in Mexico, Canada, South America, and even Iceland, and, we also benefit because we put it back into the highest value end-use products ? food and beverage containers. Dr. Brady pointed out that when China and India get to our standard of living, there isn’t going to be enough of all raw materials to go around. That means that reusing all materials will eventually become necessary and that recycling will become a significant industry, rather than to remain a “nice thing to do.”

During our interview, I learned that Dr. Brady had taken a leave of absence from the company in 2009 to become the Interim Dean of Education at the University of Toledo. He said, “At first, I was judged by the faculty and staff at the college to be a poor choice as the interim dean. However, I actually had the advantage of being completely dependent upon the expertise and experience of the faculty and staff at the college. I made a personal commitment to get to know each and every person in the college and to understand the personal and professional backgrounds of everyone. As a result, we were able to work together to craft a mission and strategy for the future and to create a climate of success going forward.”

Therefore, I wasn’t surprised to learn that Dr. Brady’s grandfather founded the University of Toledo’s college of secondary education. His mother, an aunt, his two sisters and both grandmothers all taught school. He doesn’t just “talk the talk”; he “walks the talk.” When he was interviewed by Plastic News prior to being inducted into the Society of Plastics Industry Hall of Fame in, 2012, he said, “My goal is to help anywhere I can to make education better. If we don’t educate our kids in this country, we’re lost. Our only competitive advantage is being able to be entrepreneurs. The rest of the world can catch up in everything else, so we better figure it out. And, there are not going to be enough unskilled jobs in the future, so you better educate people so they can go out and create their own jobs.”

Dr. Brady emphasized the importance of education and training in the whole economic development equation by saying, “In a sense, I think I could reduce the entire economic development issue to just this one issue. That is, if we spent every one of our economic development dollars on building a world class K-16 education and training system, I truly believe that economic development would happen naturally as a by-product of that initiative.” He reiterated a point that he had made to the mayor of Toledo a few years earlier:

  • Higher per-capita income is a by-product of higher-paying jobs
  • Higher-paying jobs are a by-product of knowledge-based commerce
  • Knowledge-based commerce is a by-product of education and talent
  • Talent and education are by-products of a superior K-16 school system, substantive trade and skill development institutions, and a superior teaching and research university.

I completely concur and made similar points in my book, Can American Manufacturing be Saved? Why we should and how we can, as well as the several blog articles I have written about workforce development and attracting the next generation of manufacturing workers. Manufacturing jobs are the foundation of our economy and the middle class. We must strengthen our manufacturing industry to create more jobs if we want our children and grandchildren to have an opportunity to live the “American Dream.”

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