Guest post by Peter Morici “The fact is nothing the Fed does can appreciably accelerate U.S. economic recovery or stem deflation as long as China continues to print yuan, buy dollars and U.S. securities, and make its products woefully cheaper than its comparative advantage warrants in the United States and Europe.”

Through the boom years of the last decade, Beijing printed yuan to purchase hundreds of billions of dollars in foreign exchange markets. That made the yuan and Chinese products on U.S. store shelves artificially cheap, and imports from China, coupled with higher prices for imported oil, pushed the U.S. trade deficit to more than five percent of GDP from 2004 to 2008.When Americans spend that much more abroad than foreigners purchase in the United States, American goods pile up in warehouses and a steep recession will result, unless Americans spend much more than they earn or produce.During the boom, China facilitated such folly by using its dollars to purchase U.S. Treasury securities, and that kept U.S. long interest rates artificially low, even in the face of Federal Reserve efforts to reign in spending.From 2003 to 2006, easy terms prevailed on mortgages, homeowner lines of credit, car loans, and credit cards even as the Fed raised the federal funds rate. Americans borrowed against their homes, pushed real estate prices to unreasonable levels, and spent on Chinese goods at Wal-Mart until the credit bubble burst in late 2007 and 2008.China continues to recklessly print yuan to buy dollars and U.S. Treasuries, and all those yuan are creating inflation and real estate speculation in China that Beijing can’t contain.
With the dollar still overvalued by some 40 or 50 percent against the yuan, the U.S. trade deficit with China, and other Asian countries practicing similar currency mercantilism, is growing again. This deficit saps demand for U.S. goods and services, slows U.S. recovery, and suppresses U.S. land values and fuels fears of deflation in the United States, even though the U.S. banking system is flush with cheap credit from the Fed.
The fact is nothing the Fed does can appreciably accelerate U.S. economic recovery or stem deflation as long as China continues to print yuan, buy dollars and U.S. securities, and make its products woefully cheaper than its comparative advantage warrants in the United States and Europe.
Coupled with its high tariffs and administrative barriers to imports on anything the Chinese can make themselves, no matter how awkwardly or inefficiently, Beijing is hogging growth and jobs, and spreading unemployment and budget misery among workers and governments from Sacramento to Athens.
This past weekend, Beijing announced it will permit some more exchange rate flexibility but we have heard those words before. China will likely permit the yuan to rise slightly against the dollar-much less than six percent a year-while the true value of the yuan rises much more, thanks to Chinese modernization and productivity improvements.
China’s announcement is a cynical ploy to assuage critics less than a week before G20 meetings, and without a substantial one-off revaluation of the yuan, Beijing’s words are hypocritical and selfish.
China’s yuan policy makes the Fed nearly irrelevant but for crisis management-bailing out big banks and European governments that make fatal mistakes.
Worse, President Obama’s failure to take strong action against Chinese currency manipulation-for example, a tax on dollar-yuan conversion to make the price of Chinese products reflect their true underlying cost-crippled the jobs creation effectiveness of his $787 billion dollar stimulus package and delivers ineffective his broader efforts to resurrect the U.S. economy.
Obama’s exclusive reliance on diplomacy forfeits U.S. monetary policy to Beijing, renders impotent U.S. fiscal policy, and visits enormous pain on American workers.
Peter Morici is a professor at the Smith School of Business, University of Maryland School, and former Chief Economist at the U.S. International Trade Commission.
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423,000 jobs, $24.6 billion in annual payroll, $136 billion worth of products sold.
Just the facts on the medical technology industry.

These three facts alone make a compelling case for medical technology focus as part of your precision machining business plan- but wait- there is more.
12.5% increase in number of workers in this industry 2005-2008;
11.4%- increase in payroll;
11.6% – increase in value of products sold.
Medical Technology Industry Salaries: 40% above National Average.
These are just a small sampling of the facts in the latest report from AdvaMed prepared by The Lewin Group.
Top ten states for Medical Technology Industry Employment: California, Minnesota, Massachusetts, Pennsylvania, Florida, new Jersey, Indiana, New York, Texas, and Wisconsin.
You can get the full report on the Medical Technology Industry HERE.
Nothing like the facts…
Joe Friday photo credit.
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Austenitic Grain size is an important aspect in the specification and selection of steel for our engineering projects.

This makes a difference!

 Here are five points to help you make sense of austenitic grain size and its influence on our work.
1) The variation in mechanical properties, response to simple heat treatment, and many other properties cannot be explained solely by chemical composition.
2) While the matter of grain size does not take away from the importance of chemical composition of steels, grain size  does shed light on how the steel may be expected to perform in fabrication or service.
3) The method most widely used in steel is called the McQuaid Ehn test, and it uses plate IV in section 10 of  ASTM E112 Standard Test Methods for Determining Average Grain Size. A full discussion of the procedure can be found in Annex A3, Paragraph A.3.2.1.2 (and subsequent) of ASTM E 112.
4) In ASTM E 112, grain sizes can range from grain size number 1 (coarse grain) to grain size number 8 (fine grain).
5) Impact strength at a given hardness, yield strength, % elongation, distortion in heat treatment , machinability,and ability to be plastically deformed are all material characteristics that are influenced by grain size.
While the origins of grain size determination were visual and chart based, today many laboratories use software to perform automatic image analysis. Utilization of semi-automatic digitizing tablets or automatic image analyzers to measure grain size is described in ASTM Test Methods E 1382.
For more information about the role of fine grain size in your machine shop, click here.
For more information about coarse grain size in your machine shop, click here.
Image of microscope reticle courtesy of  Klarmann Rulings Inc. 
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The recovery of the precision machined products industry is  obvious in our latest PMPA Business Trends Report.

16 point gap between 3 month and 12 month moving average for sales!

 We have been  calling our new level of sales “The New Normal.”  While we have lost a decade in terms of sales volume, we are at sustainable levels of sales because of the lessons and adjustments that we made over the decade. The 16+ point gap between the 3 month moving average (97.3) and 12 month moving average (81) for sales makes a case for cautious optimism.
(OK, perhaps I am understating this a bit!)
Sales Index: down just 5 points to 100  from March 2010  value of 105.
Average Length of First Shift: 42.5 hours for April, compared to 38.1 for CY 2009. only 3 % of respondents report less than 40 hours.
Sentiment for the next three months:
Sales: 88% of respondents say Same or better.
Lead Times: 93% of respondents say same or longer. Shops are getting busy.
Employment: 99% of those reporting expect employment in their shop to remain the same or increase.
Profitability: 88% expect profitability to remain the same or improve over the next three months.
You can read the full report here: PMPA APRIL DATA.

 
Chatter costs money when you reduce the productivity of the machine by slowing it down  to make the vibration go away.

Chatter.

Conventional wisdom states that there are two kinds of chatter- Forced and Self Induced. Some shop guys like to think its caused by the material.
Forced chatter is a result of alternating cutting forces  that result from
1) Interrupted cuts (milling);
2) Machine vibrations such as out of balance motors,  spindles, gear or shaft irregularities, bad couplings or bearings, (Loose motor mounts and weakened or stretched) couplings;
3) Load on tool / workpiece changing as a result of acceleration or decceleration;
4) Vibrations being transmitted through the machine and foundation from other equipment.
If forced vibration is what you have, confirming the integrity of  the machine tool and its power train is a critical first step. Reducing the feed per revolution is one way to determine if it is the variation in the cutting process that is forcing the vibration. Changing the SFM or RPM’s by at least 25% is also something to try (increase or decrease!)
Self excited chatter is induced by a change in the cutting forces themselves, and is where I place the chatter that may be caused by the material.  Self excited vibrations can be distinguished from forced vibrations in the machining system  because self excited vibrations stop when the cutting does. Forced vibrations are not dependent on the cutting process, and so continue even when the tool is not in the cut. Self excited chatter can be caused by:
1) Change in forces needed to cut caused by differences in the material-  Material characteristics (such as workhardening or microstructural differences) that result in variation in chip thickness.
2)  Unstable built up edge (BUE) forming then breaking off causing variation in the cutting forces
3)  insufficient Stiffness of the workpiece,  spindle,  tool   and tool holding (think deflection and too much length).
To eliminate self excited chatter decrease the length of the tool in the cut,  shorten the tool holder, or substitute more rigid tooling and support materials (a carbide boring bar  deflects less and can make three or more times heavier a cut  than one made of steel for example) .
Still think it’s the material? Here’s my Metallurgist’s tip:  Look and see if you have  changing build up edge conditions on the tool that exhibits chatter. If  the self excited chatter is due to material such as an unstable built up edge (BUE)  forming,  try increasing the RPMs / SFM. Spindle speeds that are too slow allow workpiece material to weld to the tool edge  (pressure weld) and build up.This creates higher forces until it sloughs off.  Then forces go back to normal, and build up again until…
Higher RPMs help to keep BUE stable and  under control. And  they allow you to run faster cycle times, contributing to profits.
Bottom line: Chatter doesn’t always mean you need to slow down.
Photo credit.

When present in substantial amounts, Nickel provides a number of benefits to steel.

And its money too!

Nickel’s main contribution to steels is making them more forgiving of heat treatment variations. Think of it as the Heat Treater’s Friend.
Nickel lowers the critical temperatures, while widening the the temperature range for effective quenching and tempering. Nickel also retards the decomposiition of Austenite. Since nickel doesn’t form carbides, it doesn’t complicate the reheating for austenitizing process either.
Nickel contributes to an easier and more likely to be successful heat treatment.
Here are 5 Contributions Nickel makes to our alloy steel parts:

  1. Improved toughness (especially at low temperatures!)
  2. Simplified and more economical heat treatment (Money saved!)
  3. Increased hardenability (depth of hardness achievable)
  4. Less distortion during quenching (more good parts after Q&T!)
  5. Improved corrosion resistance (See this link–  2.1 % of GDP lost to corrosion!)

In addition to its appearance in the credits for 43XX, 46XX, and 86XX alloy steel grades, Nickel is a major component of Stainless Steels, Invar, Monel, and Inconel.
Machinist hint: When you see Nickel as a major ingredient in steel,  avoid tool dwell and light cuts. Nickel contributes to a material’s workhardening ability.
Photo credit.
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On April 26, 2010, many of us were in Pittsburgh attending the PMPA’s National Technical Conference…

Connecting to find 'Tools You Can Use'

 …while OSHA Administrator David Michaels announced the OSHA spring regulatory agenda.
This agenda only represents the items that OSHA is moving agressively forward on at this time.  these are items Michaels characterized as “long overdue.”
Ambitious agenda.

Items that will impact your precision machining shop include:

  1. Injury and Illness Prevention Program
  2. Changing the Occupational Injury and Illness Recording and Reporting Requirements
  3. Adding a Musculoskeletal Disorders column to the OSHA 300 log
  4. Increased enforcement of Ergonomics under the “General Duty” clause.
  5. Beryllium
  6. Walking Working Surfaces
  7.  

The Injury and Illness Prevention  ‘Plan-Prevent-Protect’ Program is a significant expansion of these kinds of requirements in the Labor Department. The proposed regulatory actions  require employers to develop programs to:
Plan –The Department will propose a requirement that employers and other regulated entities create a plan for identifying and remediating risks of legal violations and other risks to workers.
Prevent-The Department will propose a requirement that employers and other regulated entities thoroughly and completely implement the plan in a manner that prevents legal violations.
Protect- The Department will propose a requirement that the employer or other regulated entity ensures that the plan’s objectives are met on a regular basis. 
“Employerswho fail to take these steps… will be considered out of compliance with the lawsubject to remedial action.”-  excerpted from the Spring Agenda Narrative Page .
This sounds to me  remarkably like a means to get even more paperwork violations- a  pretext to fine employers even when no injury has occurred.
Copy of the Semiannual Regulatory Agenda
David Michaels photo credit Industry Week
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Ryan at Change The Perception discovered this CNN video about Machining.

This isn't old time manufacturing!

Here’s the Video.
Ryan, thanks for sharing this video about the New Blue Collar. About how we make a difference by making things.
Thanks for your work to help our industry Change the Perception.
And  a tip of the hat to CNN Edition for this outstanding video.
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The PMPA Business Trends Index of Sales for March 2010 reached the 100 mark.

This is auspicious because that 100 value means that our sales level in March 2010 is essentially the same as our average sales for the year 2000, which is the base year  (2000=100) for our index calculation.

Finally back to 2000 sales levels in March of 2010.

We have lost a decade!
Hooray!
Hooray- because we are up 36 points from the low of May 2009 at 64.
Hooray- because we are achieving those year 2000 sales numbers with the lessons we learned during the lost decade: lean operations, lean setups, cellular operations. Working smarter. Maximizing use of our equipment’s capability. Tapping the ingenuity of our savvy employees.
Here is our narrative from the  March Business Trends Report  
Now, about that Lost Decade:
During the lost decade, we learned which jobs we could do where we added sufficient value to be the manufacturer.  And which jobs were of so little value added that they would inevitably be made in low cost economies.
During the lost decade, I think we also learned the lesson that some customers are bullies and not profitable- more difficulties than they are worth.
And as we continue our lunge to profitability, I am seeing many signs that our industry knows what to do with those customers.
Arrogant demands get their due.

Plank:
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Listen! There is a reason they have canaries in the coal mine.

As a steel company Metallurgist and Quality Director, I was the guy who got the call to visit a shop because the material we sent wasn’t machining right.
“This stuff won’t drill! Help!”
“This stuff is killing my OD form tool. Can you check the steel?”
“This steel you sent is acting crazy. It machines fine on one machine, but not on the other one.”
As the fellow responsible for the processes and quality system that produced the bars, and having visited my hot mill upstream suppliers, I was always confident that I had provided conforming product.
But how could I make sense of the problems reported?
My solution was to always look at the wrong tool- first.
If they complained about the drill, I asked them to show me the cut off tool.
If they complained about the rough, finish form, or shave tool, I asked them to show me the cut off tool first.
They said “Hey Mr. Free you aren’t paying attention. I said the drill is giving me trouble, not the cut off tool.”
To which I  cheerfully replied “Yes?”
After letting that sink in for a bit I would ask the following appreciative inquiry type of question to lead their thinking:
If the cutoff tool sees every aspect of the steel provided-  the very surface of the outside diameter (OD), the sub-surface, the mid-radius, the core, and it does not have any abnormal issues resulting from this material, what is there about this material that you think would allow it to affect this one tool, but not the cutoff?”
Then we focused on the aspects of the operation that inevitably were found to be the cause.
How does the steel know to only interfere with the drill, lets say? Or the the finish form? While leaving the cut off tool unscathed?
While there can be material conditions that are specific to a certain zone in the steel and thus would manifest on a particular tool, that conditon would also have an impact on the cut off.
 If the cut off  tool is A-OK, it’s probably not the steel.
This is the tool that will tell the tale.

It may not look like a canary, but a cutoff tool can sing a song about your process, if you can listen with your eyes.
Canary.
Cutoff.
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