Dual Perspectives

Dual Perspectives: Digitalization, Has it Come to Heat Treat Operations?

op-ed

Changes are inevitable, but the world today is shifting oh so rapidly, keeping us on our toes. Two men from different parts of the world, both with significant experience within the heat treating community, reflect on the implications of these changes in the heat treat industry. With each new topic, will their views align?

The experts are Thomas Schneidewind, editor-in-chief of heat processing magazine, and Doug Glenn, publisher and founder of Heat Treat Today. Thomas’s expertise lies in the European market while Doug’s resides in the North American market. We will feature their responses in each print magazine. Will their views run parallel or perpendicular? Time will tell. Enjoy this sixth installment of an ongoing column, first published in Heat Treat Today’s March 2023 Aerospace Heat Treating print edition.


Has digitalization come to heat treat operations? If so, how?

Thomas Schneidewind, Editor-in-Chief, heat processing magazine

Thomas Schneidewind
Editor-in-Chief
heat processing Magazine

Have you heard about the speaking furnace in the smart heat treat operations in Kleinachenbuchbach?

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You are right! There is no speaking furnace and no city with this name – not as far as I know. But if you think about the future of hardening shops or just have a look in the R&D departments of furnace builders, you will get an idea what the heat treat shop will look like in twenty years. Two topics will clearly shape the industry: decarbonization and digitalization. Decarbonization is the leading theme; digitalization is its enabler.

Digitalization is an important catalyst that makes decarbonization possible. It enables us to create and play out a multitude of scenarios in the shortest possible time, to exchange information globally in seconds, to free ourselves from time-consuming routine work, and to conserve, develop, and pass on knowledge gained from experience. Further, artificial intelligence (AI) has already started to augment all of our businesses, and this trend will continue to accelerate over the next years. Every company needs to think of itself as a technology company, redesign its processes, and ensure its employees have the skills needed for a world where we increasingly collaborate and work with capable and intelligent machines.

Digitalization is a key to success for small and medium sized enterprises in the heat treatment industry and a key to change the traditional heat treat shop into a smart, green, and profitable company. As the owner of a heat treat operation, you can concentrate on your business. While you talk to clients, do business, and invest in green technologies, maybe someday you will talk to your furnace and it will give you answers to much bigger questions than those connected to temperature, time, and hardness.

Doug Glenn, Publisher, Heat Treat Today

Doug Glenn
Publisher and Founder
Heat Treat Today

The answer to the question is a simple “yes.” Depending on what is meant by “digitalization,” it has been in heat treat operations for a number of years. The proliferation of digital chart recorders, for example, is clear evidence of that digitalization.

What digitalization will mean in the future is a mystery. One might say that digitalization is an ever-expanding final frontier, a place where we will be able to explore strange new worlds, to seek out new life and new civilizations, to boldly go where no man has gone before! (I hope you Trekkies appreciate that reference.)

To view a video,
scan the code for “Cutting
edge technology allows Quintus Technologies to deliver
optimum technical support.”

It is, more seriously, an ever-evolving, strange new world, which currently is not widely embraced in the North American heat treat industry. Where we do see more of it is in larger companies with in-house heat treat operations. These larger companies have the IT and engineering horsepower to invest in deeper and deeper levels of digitalization.

Today, it is common for heat treat furnace manufacturers to perform computer upgrades and equipment troubleshooting remotely. It is rare, however, to see equipment servicing being performed via augmented reality (AR) where an on-site maintenance person or engineer wearing something similar to holographic glasses is helped by a “field” service technician who is hundreds or even thousands of miles away. But this type of AR-assisted field service does happen. For example, a hot isostatic press manufacturing company is promoting their ability to perform remote AR-based service. To view a video, scan the code below or do a web search for: “Cutting edge technology allows Quintus Technologies to deliver optimum technical support.” Pretty inspiring.


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Energy: Is There a Crisis Affecting Heat Treaters Worldwide?

op-ed

Changes are inevitable, but the world today is shifting oh so rapidly, keeping us on our toes. Two men from different parts of the world, both with significant experience within the heat treating community, reflect on the implications of these changes in the heat treat industry. With each new topic, will their views align?

The experts are Thomas Schneidewind, editor-in-chief of heat processing magazine, and Doug Glenn, publisher and founder of Heat Treat Today. Thomas’s expertise lies in the European market while Doug’s resides in the North American market. We will feature their responses in each print magazine. Will their views align? Time will tell. Enjoy this fifth installment of an ongoing column. This column was first published in Heat Treat Today’s February 2023 Vacuum print edition.


To what extent have high energy prices affected heat treaters?

Thomas Schneidewind, Editor-in-Chief, heat processing magazine

Thomas Schneidewind
Editor-in-Chief
heat processing Magazine

In Europe, many companies are in shock. The energy crisis threatens the existence of energy-intensive companies. The hardening industry is coming under pressure as sharp price increases for electricity and gas lead to business losses. This is because the higher prices cannot be passed on to the customers, whose contracts do not allow price increases during the term of a contract. Most hardening shops are small or medium-sized businesses, while their customers are large companies and corporate groups.

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Hardening plants must find short-term solutions to cushion the cost shock and ensure the survival of their business. Add this with a view to the long-term goal of decarbonization. Because, in the future, process heat must be carbon free. Whether energy-intensive production is still possible in Europe in the future will be decided by the flexibility and inventiveness of the industry. The task now is to find intelligent answers and to reduce the use of fossil fuels more quickly than planned.

An important step in this direction is the modernization of existing plants – retrofitting can become the efficiency turbo that saves the day in difficult times. Hardening plants should further develop electrically operated equipment and strive for intelligent furnace control. The use of energy saving motors for pumps, circulators, and fans is another option. Insulation on side walls and ceilings in high temperature furnaces and energy recovery from waste heat are among the basic measures.

Modern burner technology also offers the potential to reduce energy consumption. Hydrogen as a heating gas will become an important option in the future. Hydrogen fueled burners have been around for some time but are not currently used in contract hardening shops. Because there are good ideas and positive trials, but no long-term experience and reliable cost comparisons, it will take a little longer until a significant introduction in contract heat treatment takes place. Until then, there are still some problems to be solved, such as safety, availability, investment costs, and especially the price of green hydrogen.

One thing is certain: investments are necessary. OEMs are already making high demands on future carbon-neutral processing and delivery in their contracts, since many automotive manufacturers are striving for a climate-neutral value chain – dictated by regulatory framework conditions. Hardening shops first must survive this difficult phase to then benefit from modernization investments. The aim is to offer customers carbon-neutral heat treatment. Companies can only achieve this by using green technologies. There is no other way.

Doug Glenn, Publisher, Heat Treat Today

Doug Glenn
Publisher and Founder
Heat Treat Today

In North America, energy is typically one of the top three expenses in nearly all heat treat processes. Commercial heat treaters know this well because it is their business to know the costs associated with their livelihood. Manufacturers with in-house heat treaters, on the other hand, often don’t properly allocate all the true costs associated with their heat treating processes. However, energy costs are fairly easy to allocate, even for them, and it’s safe to say: energy prices are skyrocketing.

The impact of rising energy prices can be measured in the price for each BTU that goes into the heat treat process. Often, 50% to 200% increases have not been unusual in the U.S.

But less obvious costs that are not so easy to measure also impact heat treaters. For example, transportation, which is energy intensive, adds to overall processing costs, especially if not done in-house.

Even LESS obvious is the effect that rising energy costs have on quality, innovation, and standard operating procedures (SOP). When corporate profits plummet due to rising energy costs, all aspects of the business are scrutinized, not just the areas where energy is most intensively used. This oftentimes results in cuts to “non-essential” expenses, which may mean reducing new product or process development initiatives, cutting back on borderline or “unnecessary” quality or safety measures (!), and re-examining SOPs to make further cuts.

The rising cost of energy could even impact the competency of heat treat operators. During COVID, I spoke to a nurse who explained that quality of care was reduced when a large number of nurses left the profession because they chose not to take the vaccines or boosters. Patients receiving emergency medical care did not notice any shortage of personnel, but the fact was that the nurses filling the critical roles were not as proficient or qualified as the expert nurses they replaced. In a similar way, when energy prices skyrocket and cuts must be made, the internal allocation of resources may compromise some aspects of the business that are not as clear to the customer.

When energy prices rise as drastically as they have, companies will examine how they can cut costs and help maintain profits, which is a GOOD and appropriate thing. It will take time for heat treaters to adjust to the recent energy price spike. Adjustments won’t be cost-free. The question is: Which part of the company will pay?


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DUAL PERSPECTIVES: Government Policy and Nuclear Power Initiatives

op-ed

Changes are inevitable, but the world today is changing so rapidly that it’s constantly keeping us on our toes. Do two men from different parts of the world, both with significant experience within the heat treating community, have vastly different perspectives on the happenings in the heat treat industry?

We want to find out, so we asked a question that focuses on the world of heat treating to Thomas Schneidewind, the editor-in-chief of heat processing magazine, and Doug Glenn, the publisher and founder of Heat Treat TodayThe question: How does government policy regarding ESG in the U.S. and nuclear power initiatives in Europe impact in-house heat treaters?

Thomas’s expertise lies in the European market while Doug’s resides in the North American market. We will feature their responses in each print magazine. Will their views align? Time will tell. Enjoy this fourth installment of an ongoing column. This column was first published in Heat Treat Today’s  November 2022 Vacuum print edition.


How does government policy regarding ESG in the U.S. and nuclear power initiatives in Europe impact in-house heat treaters?

Thomas Schneidewind, Editor-in-Chief, heat processing magazine

Thomas Schneidewind
Editor-in-Chief
heat processing Magazine

The energy crisis paralyzes Europe. The European Union has been arguing for a long time about which energy is green. Finally, the European Commission classified both nuclear energy and gas-fired power plants as green energy production. This was a compromise between France and Germany in the discussion about the taxonomy that regulates in which energy sources investments should be made. Today, environmental associations are suing against this compromise, considering neither nuclear energy nor gas-fired power plants to be green energy.

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However, the discussion is long outdated. The Russian war of aggression on Ukraine has changed energy policy. Many nuclear power plants in France are at a standstill. Germany no longer receives gas from Russia, and the sabotage of the Nord Stream 1 and 2 pipelines is a politically motivated attack on the European energy market. Today, Europe is suffering from a major energy crisis. There has never been such a crisis in the energy sector in Europe since the Second World War. There is too little energy on the European market. At the moment, the focus is on security of supply.

This crisis threatens the existence of energy-intensive companies such as heat treatment shops. The hardening industry is also coming under pressure because it cannot pay the high electricity and gas prices. Entrepreneurs must find short-term solutions to cushion the cost shock, and ensure the survival of their business -with a view to the long-term goal of decarbonization. Because in the future, process heat must be CO2 free. A clear trend in this context is the switch from gas-heated industrial furnaces to electrically heated systems, whether resistance heating or induction. Managers must face these diverse issues today and respond quickly

Experts and practitioners will be talking about sustainability, materials, processes, and innovations in heat treatment at several events this fall. For example, in October, after a two-year pandemic break, the Hardening Congress (HK) was finally held again in Cologne. Here, too, the energy crisis was a dominant topic. We are talking about the future of Europe which must compete with the U.S. Many investment decisions are being put on hold because the uncertainty in Europe is currently too large. Europe, but especially Germany, faces a new recession.

Doug Glenn, Publisher, Heat Treat Today

Doug Glenn
Publisher and Founder
Heat Treat Today

Tremendously. A distinctive mark of the U.S. is that we’ve trusted the Market – what Adam Smith called the “Invisible Hand.” We haven’t believed that economies need to be planned or managed; attempts to manage or plan an economy result in more damage than good. We’ve believed that if proper natural or biblical law guardrails are established and enforced, the economy would run itself, self-adjusting as necessary. Today, many have lost faith in the Market. Instead, we put our faith in political processes and political leaders to handle the economy. Because we’ve lost faith in the Market, questions such as the one we’re addressing today make sense to ask. Government policy should have nothing to say about the type of energy we use, the people we hire, or the ideals we hold. Nonetheless, that is NOT the world we live in, so let’s address the question.

Nuclear Power Initiatives

This is really not an initiative; it is more of a “de-initiative” – a closing down of nuclear power plants in Europe (except France) – and the incentive to do so is not economic. According to those who know, nuclear is the cheapest, most reliable form of energy, vastly less expensive than “renewables.” So, in the hands of the Market, nuclear and natural gas generation power plants would win the day. Nuclear is being abandoned for purely political reasons. The effect on heat treaters and all other consumers of electricity: higher prices for energy, either in the form of explicitly higher prices per BTU or higher taxes to incentivize more expensive “renewable” energy sources.

Environmental, Societal, and Governance

As far as ESG goes, government policies in these areas will only increase the cost of doing business.

ONE of the three categories represents an area where the government might have a right to be heard: environmental. But even there, government’s scope is vastly overplayed – that is, if you have faith in the Market! Societal and governance are recent (non-economic) constructs being forced on businesses, NOT for the benefit of the end-consumer, but for the benefit of a vocal minority who believe the world should be a certain way and are using government policies to make it so.

For in-house and commercial heat treaters, ESG pressures and government recommendations or policies will raise the cost of doing business and ultimately the cost of the final product for consumers with very little measurable benefit for anyone. For in-house and commercial heat treaters, ESG pressures and government recommendations or policies will raise the cost of doing business and ultimately the cost of the final product for consumers with very little measurable benefit for anyone.


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