Your Blackberry, iPhone or mobile device is soon to become your credit card

Home > Archives

Manufacturing

Collapsing product lifecycle. The connectivity of the Internet of things. Mass customization. Digitization, robotics and the cloud. Design based on crowd thinking. Rapid prototyping and deployment. Faster time to market. Additive manufacturing. Are you ready for the new world of manufacturing? Jim Carroll helps to get you there!”

Arrow
Arrow
ArrowArrow
Slider

Some of the largest manufacturing and industrial organizations in the world have engaged Jim to help them think about opportunities for innovation. DaimlerChrysler arranged for his participation in a two day global strategy summit in Stuttgart, Germany, in order to provide insight on trends in the automotive industry. He recently keynoted the IMX - Interactive Manufacturing Exchange Congress in Las Vegas with an audience of over 2,000 senior manufacturing executives. Jim's other manufacturing and industrial clients include • Magna International • United Technologies • Camstar Systems • Genesis Systems Robotics Conference • Siemens • PPG • Chrysler • Satisloh North America • FMC Lithium • Motorola • The World Congress on Quality • Caterpillar • FMC Food Products • Techsolve Ohio • Parker Hannifin • Methanex • Packaging Machinery Manufacturers Association • Materials Handling Association of America • Silgan Corporation • FMC BioPolymer and many more. .

Recent Posts in the Manufacturing category


The folks at the Precision Metalforming Association were putting together their 75th anniversary issue of Metalforming magazine, and wanted to share with their readers that it’s better to align yourself to the trends of the future rather than the opportunities of the past.

And they found me! We had a long interview, which appeared in their July publication. Parts are reprinted below.

I do A LOT of manufacturing keynotes. The reality is, tomorrows’ manufacturing is unlike that of today.

You can choose to adopt to the future, or wish you were in the past. So — are you George, or Fred?


2017 and Beyond by Brad Kuvin
A futurist and expert in trends and innovation examines what he refers to as the “modern-day leadership dilemma”–heading toward the Jetsons when you have a bunch of Flintstones around!

Futurist Jim Carroll noted in a blog post earlier this year that “while the majority of my audience appreciates a whirlwind ride into the future, there are others who just wish the future would go away… Leaders today must steer their organizations into a fast-paced future—through the shoals of disruption, the emergence of new competitors, technology, automation and other challenges—while understanding that there is a core group that will do little to embrace that change. It’s the Flintstones and the Jetsons, in one workplace!

Carroll has been providing his insights and speaking to organizations about the future for more than 25 years.MetalForming asked him to help us commemorate PMA’s 75 anniversary by sharing his manufacturing outlook over the next 5 to 10 years, and explaining why it’s critical that we embrace and address the change that’s coming.

At the crux is the increasing need, he says, to react more quickly than ever to changing/evolving customer preferences, and the shortening of product lifecycles. Manufacturers must be driven to react quickly to new demands and requirements. In the shop this plays out as more tooling adjustments and changeovers, more flexible scheduling and the ability to react to a slew of design changes.

Upside-Down Innovation

This represents a complete turnaround from how manufacturers currently think about doing things, Carroll says. And, the impact ripples through the supply chain. Suppliers must, for example, become rapid prototypers, and master the iterative design process.

We used to be able to design a product, build a model, test it and then launch production,” Carroll says. “Now it’s design, test, redesign, test, redesign, etc…an iterative process that, thanks to disruptive technologies such as additive manufacturing, allow suppliers to efficiently optimize product designs and, ultimately, provide better-performing products.”

For suppliers living in this world of upside-down innovation, “it’s critical, looking toward the future, to become unstuck from the reactive mode,” Carroll notes. “Instead, suppliers must become active partners with their customers in this iterative design and rapid-prototyping cycle. Be more active and less reactive, and look for opportunities to innovate.”

Carroll’s above-referenced blog postnotes that “there remain folks who just refuse to participate in the inevitability of the future, and that can be a significant leadership, strategic challenge…Many people today feel that the world is moving way too fast for them, and that the pace of change is overwhelming.

In a recent poll of seminar attendees, Carroll found that many organizations do in fact feel overwhelmed by change, and that many executives believe that they don’t really need to do anything to deal with it.

“In other words,” Carroll says, “they believe that the future can be safely ignored. I use the ‘Jetsons-meets-the-Flintstones’ concept as a joke, but it’s not—this is a real and substantive leadership issue. As a CEO or senior executive, how are you going to align a fast-paced future—one full of challenge and opportunity—to an organization where a significant number of people don’t think that the future will impact them?

Over the years, I’ve done many talks within the manufacturing industry, putting into perspective the real trends and opportunities for innovation that will allow for reinvention of this sector. Lots of CEOs are bringing me in for a leadership meeting, knowing that their future will come from aligning to fast paced trends (as opposed to wishful thinking as found in the current political environment). Much of the opportunity for innovation in the  sector involves advanced technologies, digitization, new manufacturing methodologies and process — and of course, 3D printing or additive manufacturing.

I’ve been speaking on stage about 3D printing for well over ten years. The concept of having a printer that can ‘print’ physical things is a fascinating one, and is evolving at a furious pace. Earlier this week, I did a talk for a manufacturing organization in New Haven, CT, that included a detailed overview of who is doing innovative work in this area. I’ll blog about that later.

For now, though, a lot of the opportunity from 3D printing comes from the ability for rapid prototyping and design. It unshackles organizations from having to commit to a full production run upon finalizing a product design; instead, it leads to an iterative process in which the product design can be continually changed. In addition, there is quite a bit of ‘grassroots’, tinkering innovation around 3D printing, with folks fooling around in their garage or home workshop to developing fascinating new products. They can then use contract 3D printing manufacturers to turn their ideas into a physical product.

To that end, here’s a great story! Last year, when I was the opening keynote speaker for the annual PGA Merchandise show, I spoke to the Professional Golfers Association as to how quickly 3D printed golf clubs will become an opportunity for innovation within the game. Watch the clip.

Imagine my surprise the other day when I’m out for a round at my home golf club, Credit Valley Golf and Country Club, and meet a fellow member named Gary Woolgar. He’s actually 3D printing his own custom wedges, using his first prototype on that day. (I’m not quite sure I understand the design concept, but then again, my golf game is a bit of a shambles right now).

It’s such a fascinating story that I told it on stage last week when I headlined a session on manufacturing innovation for a global, $2 billion company. Watch this clip too!

This is one of the most exciting aspects of 3DPrinting — the world around is changing at a furious pace, and sometimes, its driven by engineers who have an idea, the tools to test the idea, and the initiative to make it work. Organizations need to embrace the same type of thinking: grassroots innovation, tinkering, and trying out new ideas, methodologies and technologies.

If you are in the manufacturing sector, you need to empower your team to do the types of things that Gary is doing. It’s only be experimenting with the tools of the fast pace future that you can discover the opportunities they will present. In other words, you need more guys like Gary around!

 

We seem to live in two parallel worlds at this moment: the fanciful, political, “let’s make a wish” or “yell and scream” political world, and the real world. I don’t know about you, but I’m with the real world, and it’s obvious that others are too. To that end, I’m doing an increasing number of economic development talks that take a look at the real trends driving our world forward.

Case in point: I’m headlining the Nevada Economic Development Council conference this September in Las Vegas. We’ll have economic development folks, elected officials, industry representatives — all looking for insight on what comes next in terms of opportunity.


In my mind, economic opportunity comes from linking to the fast paced trends that envelop our world today. As the session description notes on my keynote: “He is an authority recognized for his deep insight into the cutting edge trends of our time, including autonomous vehicle technology, sensors and the Internet of Things, 3D printing, virtual reality, alternative energy generation and storage technologies, genomic medicine and healthcare virtualization, advanced robotics and artificial intelligence, blockchain and virtual cash, machine learning and robotics, crowdthinking and next generation R&D.”

Around the world, we are building a giant new machine, and new opportunities abound. They’ll involve new skills, big bold innovators, fast new technologies, and obviously big investments. Nevada woke up to the future when Tesla established the Gigafactory outside Reno, and knows that its’ future will come from aligning itself to other, similar trends.

If only other regions and people could think like Nevada instead of hitching themselves to a failed politician from the land of make believe.

Similar to this event, I’m also headlining (for the 3rd time in 16 years!) the International Asset Management Council annual event in Richmond, Virginia this fall. This is a group that consists of corporate relocation folks for Fortune 500 companies — people who analyze where they might place their next factory or manufacturing facility. They’ve asked me to come in and do a talk around the future of manufacturing, with an eye to better understanding the trends involving the reinvention of this critical sector of this economy.  (Hint: the old jobs aren’t coming back. New jobs are appearing all the time).

As the keynote description outlines: “Collapsing product lifecycles. Mass customization. Digitization, robotics and the cloud. Rapid prototyping, sketch to scale, and agility-based business models … are you ready for the new world of manufacturing? While popular media and opportunistic politicians portray a picture of a sector in crisis, smart manufacturing executives are furiously busy with innovation, reinventing their capabilities, processes and business models using advanced ideas, materials, methodologies and technologies.”

Regions that can align themselves to the reality of future trends, and set the right tone and welcome mat for innovation will discover the future of economic success. I’m pleased to be doing what I can to help people understand the real future — not a fake future dreamed up in someone’s mind.

Location intelligence was the hot new opportunity 20 years ago as spatial (GIS) data came to be a big part of the world. 20 years on, it still is. My oldest son is building a fabulous career working in the industry – he’s a leading expert in the use of tools such as ArcGIS, for example.

But move over for spatial data bubbles — all of us are about to become immersed in many different bubbles, and the implications are bigger than you think!

What is a spatial data bubble? It’s a phrase I’ve coined as I’ve come to spend more time thinking about what happens when we add location oriented data to data-sets that will envelope us in multiple dimensions. I first hit upon the realization of how important they will be when I was working out with my personal trainer one day at the gym, and was continuing to ensure she understood the impact of emerging smart clothing technologies upon exercise routines.

The simple fact is, I drive my personal trainer nuts when I’m at the gym. She will try and get me to do a certain routine that has my limbs or torso moving within a certain defined area. If they move within that area, I’m doing it correctly. At the same time that she is trying to get me to do this, I’m busy formulating in my mind how we could reinvent exercise in the future with spatial data bubbles! Here I am on stage talking about this idea — in this case, an opening keynote for the YMCA/YWCA.

How will this work? First off, smart clothing will replace wearable technologies – read my post on that. I’ve been speaking and writing about smart clothing for years — two years ago, I outlined in a keynote for the Sporting & Fitness Industry Association that this would be a major trend to watch. Some of the bubbles which are emerging will be fascinating: a golf ball in the future will be its only little spatial-data bubble information generator as it starts to transmit real time information on speed, velocity, location and acceleration! Most sports equipment will exist in little spatial data bubbles that also align goals and objectives to performance.

So it will be with exercise routines. The  emergence of smart-clothing will solve the problem of ‘firing’ the right muscles during an exercise routine, by providing information on whether I’m in the right spatial area.  In the future, we will be buying clothes that will have a variety of embedded sensors and technology. When my trainer gets to me to do a routine in the future, and these sensors will be used to generate a data bubble around my body. She’ll be able to set a tolerance range — say, 10 or 20%. The bubble will determine if my activities are within that particular spatial range within the bubble — if so, I’ll be rewarded in some way. The better I get at the routine the lower the tolerance with the bubble will be!

If my activities stray outside the bubble — well, maybe the clothing will zap me! Big opportunities for performance-oriented exercise routines!

Spatial data bubbles will soon be everywhere! They are emerging at a furious pace with the rapid emergence of self-driving car technology.

Today’s collision avoidance systems have limited data bubbles, only looking at vehicles around them. In the future, the bubbles will be bigger, talking to the road, linking to other data bubbles, advance telemetry systems, road monitoring and lane allocation systems, and more!

The typical self-driving, connected car is putting off some 7 gigabytes of data per hour. That’s a staggering amount of information — and increasingly, more and more of it will be spatial data bubble oriented. Self-driving cars and trucks will talk to intelligent highway infrastructure technologies which might guide them on their journeys, and in effect, create a little bubble of data around the vehicle involving obstacles, other vehicles, road sensors and other stuff. Then there is stuff that is already here: peloton technology that has self-driving cars and trucks involved cars communicating their lo0cation in time and space with other vehicles so that they can travel in a space-saving, wind-resistant pack. The data bubble of a car has 360-sensing capability, looking for pedestrians, other cars and other information.

Spatial data bubbles aren’t new: they’ve been around for some time. Perhaps the best example are the robots used in advanced manufacturing systems. These robots need to have continual 3D awareness. They used to be able to operate on their own; but as their spatial data bubbles have grown, they’ve become collaborative, designed to work in proximity to people. They’ve become more spatially aware, with cameras, sonar and other tech. This has allowed them to become cognitive and quality-conscious , with feedback on whether assembly is done correctly. Increasingly, they are capable of working in multiple planes at once, with multiple axis movements. Their bubble will extend to human-operators, who might increasingly use spatial bubble technologies such as Google Glass, for remote operation, in a virtual reality scenario.

And therein lies a key point – virtual reality, more than anything else, will accelerate spatial data bubble technologies. This point was hammered home to me on the weekend when I visited Colony VR in Ottawa with my son, his girlfriend and my wife. Here I am smashing some balloons while in a virtual reality spatial data bubble!

A futurist in a spatial data bubble!

Virtual reality is going to have a massive impact on the rate of spatial-data bubble technologies, methodologies, data sets and more! VR will emerge as a significant tool for skills training, telemedicine, sports and so much more. And if you think about it, it’s all about data bubbles!

Location-oriented data is pretty easy and not terribly overwhelming in terms of quantity, because it essentially involves a couple of points on a map. Spatial data bubbles are infinitely more complex, because it will involve thousands or millions of data points involving that point on the map, and the areas above and around it.

If you think we’ve seen a data explosion in the past, we have, as they say, ”seen nothing yet!”

Spatial data bubbles are the new location intelligence!

A few months ago, I opened this conference with a resounding call to action — there are tremendous opportunities to reinvent and transform manufacturing in North America through advanced methodologies, automation, IoT (Internet of Things) factory digitization, additive manufacturing and more!

It’s captured in my blog post, Trend: Why Manufacturing Needs to Reinvent Itself, Fast! That post is a must read for anyone who wants to understand the reality of what manufacturing needs to do today to compete on a world stage.

500 people showed up for the conference in Philly!! This was typical of the many manufacturing keynotes I did last year – I had 3,000 in Chicago, and hundreds more at various other small and regional events in the sector.

There is a passion and purpose by senior executives throughout the industry, and a hunger for knowledge, on how to re-compete on the world stage, with real innovation, as opposed to “wishful thinking innovation.”

Have a watch — and listen to the folks in the room. Share this video!

Here’s my favourite quote from 2016.

It comes from Tesla Motors, and hence, Elon Musk, in a SEC filing on August 5th, having to do with the Tesla Model 3.

A car that does not yet exist, but which 400, 000 people bought into the idea of (I was one of them!)

We have no experience to date in manufacturing vehicles at the high volumes that we anticipate for Model 3, and to be successful, we will need to develop efficient, automated, low-cost manufacturing capabilities, processes, and supply chains necessary to support such volumes.”

An absolutely fascinating statement if you think about it.

Essentially, we’ve never done this before, but we are going to certainly try!

2017 will be about seeing if Tesla can pull off this bold move. Whatever the case may be, that type of thinking should be oxygen to the ears of anyone focused on disruption and innovation!

I spoke about this on stage for a manufacturing conference in front of a few thousand people in May of this year. Disruption was, perhaps, THE word of 2016. I still find a lot of people don’t really understand what it means, but this video clip puts it into perspective.

david-full-front

“Using 3D-printed wax moulds for concrete components, we will have a completely different paradigm. This is transformative technology”.

It is perhaps the most staggering piece of artwork in the whole of human history, renowned for its accuracy in the depiction of the human body . Anyone who has seen it up close comes away in awe of the fact that someone had the ability to carve such a piece from stone.

Now, imagine, that one day we will see a 3D printer that could print Michelangelo’s David utilizing concrete and other advanced materials – and that if such a statue would be placed next to the original, most people would be unable to tell the difference!

Science fiction? Not to me.

That was one of my messages in my keynote last week for the American Concrete Institute, with with over 1,000 executives from this industry in the room. My job was to outline for them the opportunities that will come to the industry from embracing fast paced trends. And I put on the table for them the idea that the boldest goal in their industry would be accomplished when someone was able to print Michelangelo’s David utilizing a 3D printer.

It’s perhaps the equivalent of the well known Turing test, which is the ultimate challenge with computer technology — could a computer have the ability to exhibit intelligent behaviour equivalent to, or indistinguishable from, that of a human?

Farfetched? No. In fact, computer companies have been pursuing the goal of the Turing test in a feverish race.

This same thing will happen in the concrete industry with 3D printing — indeed, it’s a bold goal that some people are already thinking about in terms of the transformative trends sweeping the industry today.

Every industry has, or should have the equivalent of a Turing test. Think about robotics – how quickly will this industry mature? I just toured a robotics display at a museum in Philadelphia, and one display suggested that there should be a “Jetsons goal for robotics” –” the industry will have matured when it can build a robot that will be accepted by a family, just like Rosie the Robot from the popular 1960’s television cartoon.”

Here’s the thing — we might see these big bold bets be achieved sooner rather than later. I continually emphasize to my clients that the future is happening all around them, and that it’s happening faster than they think. In China, an entire 4,305 sq foot, 2 story home has been printed with a 3D printer, with walls as thick as 
8 feet and with 9 foot ceilings. It too 45 days from start to finish, and was printed in one go at the building site.

Consider this office building in Dubai which was printed in concrete using a 3D printer (from my slide deck).

dubaiconcrete
There are fascinating trends which come from the ability to 3D print with concrete. We can get more flexible designs, with concrete that is warped or twisted. Waste is significantly reduced, new design concepts are suddenly possible, and we can cut down on the cost of manufacturing. People are talking about the fact that it will lead us to an era in which we can “design for deconstruction” — printing in such a way that when a building is eventually decommissioned, we can dissassemble it rather than blowing it up!

Where is the world of construction headed? Consider this:

Your future home might be planned using virtual reality, built with a 3D printer and inspected by a robot for quality. What may sound like a sci-fi movie could become reality in a few decades as Singapore ramps up its construction productivity and employs more efficient building methods. Building with speed and quality through high-tech, Straits Times, Hong Kong, October 2016

Of course, 3D printing is already passe, I pointed out to my audience at the American Concrete Institute: people are already talking about 4D printing — which has materials that can change shape depending on the environemt they are in!

Bottom line? Consider this comment by Archite ct James Gardiner: “Using 3D-printed wax moulds for concrete components, we will have a completely different paradigm. This is transformative technology”.

What’s the Turing test or Michaelangelo’s David in your industry? And are you prepared to think in a big and bold way to get there before others do?

 

One thing I always stress to potential clients is that they are getting much more than just a keynote or presentation for a leadership group — they are getting highly customized insight based on significant original research.

That fact has led to the client list that I have — which includes Disney, two (!) talks for NASA, the PGA of America and more….

I must admit, it’s always a thrill to read the tweets that are sent while you are on stage — realizing that you have really changed lives and changed perspectives!

edutech

You know you are doing something right when you research gets carried further into the industry:

insuretech

To that end, here’s an overview of some of the talks I’ve done this fall:

  • Disruption and Change in the Insurance Industry: a keynote for GAMA International, a global organization for leaders in the global insurance/financial services industry. There’s a tremendous amount of change happening, and much more yet to come. What did I cover in my keynote? You can read about it in my post, Insurance and Innovation: The Challenge of Change . This is one of many talks I’ve done in the insurance industry over the years; I’ve done talks for most major property and life insurance companies at one time or another, and have shared the stage with CEO’s of many of the organizations in the industry.
  • The Future of Insurance Risk: continuing on the insurance theme, an opening keynote for the client conference of FMGlobal, a leading underwriter of insurance risk in the commercial real estate space. My talk took a look at a broad range of trends that will impact the future structure of buildings, architecture, manufacturing facilities and more. Over the years, I’ve done many talks that have looked at the trends impacting the world of commercial real estate.
  • The Future of Medical Device Technology & Healthcare: a talk for an innovation recognition dinner, and then a talk for key R&D staff, for Philips Respironics, a division of Philips Medical Devices, on how the industry will be transformed through hyper-connectivity, changing consumer behaviour, the acceleration of science and much more.
  • The Future of Education. I was the opening keynote speaker for the EdNet 2016 conference in Dallas, with several hundred senior executives from the “education knowledge industry” (aka textbooks) in the room. Read at overview of my talk, Forge Ahead and Move Fast, in an article from an industry publication.
  • Wealth Management and Industry Change: a private event for CEO’s of 40 companies, each with $1 billion+ in revenue, for a private equity company. It’s one of many talks that I do to help senior executives think about the trends that might impact their lines of business and investments – read more in a blog post, Global Wealth Managers Turn to Jim Carroll for Insight on Trends .  It’s kind of cool to think that family wealth managers for such groups as the Wrigley family foundation, the Rothschild’s, the Bill & Melinda Gates family office, and the  Google and many, many others, have turned to me for insight over the years.
  • The Future of Manufacturing: keynotes for the Association of High Tech Distributors in Napa Valley; for Alignex in Minneapolis; and then a rip-roaring motivational keynote full of the latest manufacturing trends for the the Greater Philadelphia Manufacturing conference. The tweets coming out of these events have been astonishing — people in the manufacturing sector are looking for hope and inspiration, and I seem to be giving it to them in spades. Read more at my post, The Disruption and Reinvention of Manufacturing.
  • The Future of Seniors Care: two talks in Nashville for senior executives from the North American assisted living and seniors care industry. I was booked by the American Healthcare Organization and the Centre for Assisted Living, and took a look at the opportunities that come from innovative thinking in dealing with one of the most significant challenges of our time.
  • The Future of Construction, Architecture and Infrastructure: a keynote to open the annual conference of the American Concrete Institute. They admitted to me that they’ve never engaged a keynote speaker to open their event — they’ve been rather ‘stuck’ in their ways, if you pardon the pun. Will they do it again! You bet — my talk took a look at what happens when the world of concrete is influenced by fast trends — 3D printing is coming to concrete, and its coming fast!
  • The Future of Rail and Manufacturing: a talk for Amsted Rail, one of the leading manufacturers in the rail industry. This talk involved a lot of intensive preparation, with about 6 pre-planning conference call with the team bringing me in, as well as very specific, detailed research.

 

We live in interesting times, to say the least. It’s a time in which some people see the future, and see despair.

I see the future and see nothing but opportunity. And that’s the message I am carrying on stage at every event — including the industry that seems to be defining the gloom of the US election cycle – manufacturing.

philadelphiamanufacturing

The reaction to my keynotes in the manufacturing sector in the last 3 weeks has been staggering. What I’m witnessing is an industry that is seeking a message of hope, a dose of optimism, and specific guidance on how to align themselves to a future of opportunity.

What’s the reality of this industry? We live in transformative times — there is so much opportunity around us today it is staggering!

The acceleration of ideas is leading to new discoveries at a pace that rivals anything in the past: such as the rapid emergence of sophisticated new manufacturing methodologies. 3d printing or additive manufacturing, the Internet of things, process reinvention, the opportunity that comes from rapid prototyping. The massiveness that is the global maker community! The list goes on.

In the last 3 weeks, I’ve done keynotes on the future opportintities in the world of manufacturing events in Napa Valley, Minneapolis, and in Philadelphia. Folks in the industry are feeling battered and bruised, and have been convinced that the North American manufacturing sector continues in a state of decline.

What I’m witnessing from the reaction and feedback on my talks is an industry that is seeking a message of hope, a dose of optimism, and specific guidance on how to align an organization to a future of opportunity.

If you do anything in this industry today, open up your mind to the opportunity that surrounds you. Don’t succumb to the negativity that surrounds you! Those who embrace the future in this industry today are those who will own the future. If that is your mindset — give me a call!

A clip from a talk I did at the massive IMTS manufacturing show. How manufacturing is really reinventing itself.

 

Send this to a friend

<---->