Upskilling Technical Jobs in Manufacturing Scott Sheely Executive Director Lancaster County Workforce Investment Board Lancaster, PA

In the last six years… Berks and Lancaster County Workforce Investment Board sponsored two research projects using a Stay Invent the Future grant from the PA Department of Community and Economic Development; Berks and Lancaster County Workforce Investment Board sponsored two research projects using a Stay Invent the Future grant from the PA Department of Community and Economic Development; State of technology in local companies; State of technology in local companies; Capacity of local educational institutions; Capacity of local educational institutions; Center of Excellence in Packaging Operations formed using a US Department of Labor High Growth Job Training Grant; Center of Excellence in Packaging Operations formed using a US Department of Labor High Growth Job Training Grant;

In the last five years… Susquehanna Valley Advanced Manufacturing Alliance formed to articulate programming in nanotechnology and mechatronics; Susquehanna Valley Advanced Manufacturing Alliance formed to articulate programming in nanotechnology and mechatronics; Eight career and technology centers; Eight career and technology centers; RACC, HACC, and Stevens; RACC, HACC, and Stevens; PSU, Berks campus; PSU, Berks campus; RACC designated as a National Center for Integrated Systems Technology. RACC designated as a National Center for Integrated Systems Technology.

What we learned… Roughly 1/3 of all manufacturers in the area are investing in process control technology; Roughly 1/3 of all manufacturers in the area are investing in process control technology; Food and biotechnology industries are leaders because of their involvement in packaging; Food and biotechnology industries are leaders because of their involvement in packaging; Industrial maintenance technicians and related occupations are in short supply; Industrial maintenance technicians and related occupations are in short supply; Technology requires higher-level skill sets be driven down from engineers to technicians; Technology requires higher-level skill sets be driven down from engineers to technicians; Very few technical programs provide the training that is needed. Very few technical programs provide the training that is needed.

Industrial Maintenance Technician Also known as… Also known as… Industrial Machinery Mechanics ( ); Industrial Machinery Mechanics ( ); Maintenance and Repair Workers, General ( ); Maintenance and Repair Workers, General ( ); Maintenance Workers, Machinery ( ); Maintenance Workers, Machinery ( ); Industrial Engineering Technicians ( ); Industrial Engineering Technicians ( ); Numerical Tool and Process Control Programmers ( ). Numerical Tool and Process Control Programmers ( ).

Industrial Maintenance Technician Repair or replace defective equipment; Repair or replace defective equipment; Perform routine preventive maintenance; Perform routine preventive maintenance; Assemble, install, or repair electrical and electronic components, wiring, pipe systems and plumbing, drives, motors, and belts; Assemble, install, or repair electrical and electronic components, wiring, pipe systems and plumbing, drives, motors, and belts; Analyze test results, error messages, and information obtained from operators to diagnose equipment problems. Analyze test results, error messages, and information obtained from operators to diagnose equipment problems.

Industrial Maintenance Technician Basic electrical skills and circuits; Basic electrical skills and circuits; Service and repair principles; Service and repair principles; Industrial electricity and electronics; Industrial electricity and electronics; Automated motors and control systems; Automated motors and control systems; Sensors; Sensors; Mechanical power transmission; Mechanical power transmission; Fluid power (pneumatics and hydraulics); Fluid power (pneumatics and hydraulics); Programmable logic controllers (PLCs); Programmable logic controllers (PLCs); Refrigeration; Refrigeration; Robotics; Robotics; Wiring installation and maintenance. Wiring installation and maintenance.

What is Mechatronics? Mechatronics

Mechatronics Defined Part count reduction Pulleys - 45 to 0 Belts - 15 to 0 Drive sprockets- 15 to 0 Spline shafts - 2 to 0 Gearboxes- 16 to 10 Motors- 1 to 10 Bearings- 18 to 3 Line shafts- 6 to 0 Total- 118 to 23 (81% reduction) (81% reduction) Case Study in Mechatronic Design Generation 1 to generation 3 machine design, courtesy of R.A. Jones Packaging.

Mechatronics Training Project Anchored by the Hershey Corporation and its four divisions in the region as well as its corporate engineering center; Anchored by the Hershey Corporation and its four divisions in the region as well as its corporate engineering center; Train 200+ Hershey industrial maintenance technicians, electricians, craftspeople, and engineers; Train 200+ Hershey industrial maintenance technicians, electricians, craftspeople, and engineers; Curriculum was jointly developed; Curriculum was jointly developed; Faculty from area schools participated in training with Hershey staff and, eventually, become Hershey trainers; Faculty from area schools participated in training with Hershey staff and, eventually, become Hershey trainers; Educators incorporated generic skills into curricula. Educators incorporated generic skills into curricula.

Content Networking (install and troubleshoot software; use of DeviceNet; use of Data Highway, TCP/IP, and ControlNet protocols); Networking (install and troubleshoot software; use of DeviceNet; use of Data Highway, TCP/IP, and ControlNet protocols); Maintaining robots; Maintaining robots; A variety of tasks related to process controls (calibrate, install, and repair various transmitter, gages, and switches; calibrate proportional control valves and process control loops; troubleshoot and replace transducers); A variety of tasks related to process controls (calibrate, install, and repair various transmitter, gages, and switches; calibrate proportional control valves and process control loops; troubleshoot and replace transducers); Higher level tasks related to programmable logic controllers (create and modify ladder logic; install and troubleshoot PLC hardware; create and modify alternative programming languages); Higher level tasks related to programmable logic controllers (create and modify ladder logic; install and troubleshoot PLC hardware; create and modify alternative programming languages); Work with human machine interface software including Wonderware, Intellution, PanelBuilder, Interact, and RSView 32. Work with human machine interface software including Wonderware, Intellution, PanelBuilder, Interact, and RSView 32.

AAS Degree – Mechatronics Mechanical / Fluid Engineering Electrical / Electronic Engineering Industrial Mechanics 2 3 Industrial Electrical Systems 4 4 Rotating Electrical Machines 3 Process Control & Instrumentation 3 PC Installation & Maintenance 3 Introduction to Shop Machinery 1 Industrial Mechanics 1 4 Advanced PLC’s AB ControlLogix or Siemens S7 Manufacturing Fundamentals 3 Robotics & Motion Control Systems & Process Control Engineering 17 Computer Science & Engineering 14 Integrated Manufacturing Systems 3 Introduction to PLC’s Part 1 AB SLC500 2 Introduction to PLC’s Part 2 SLC500 2 Core Educational Requirements Semester College Success Strategies ORI Math Trigonometry MAT 165 or Calculus 3 English Composition COM 121 or The Environment ENV 130 or Applied Physics or Physics I PHY 150 or 250 Or Calculus- based Physics 4 Business Communications or Technical Writing BUS 06 or COM141 3 Humanities Elective 3 The Individual & Society SOC Capstone Class Application Project- Packaging 4 69 credits Courses to complete the NCIST program -----Key----- Courses that could be taught at HS or CTC credits Microcomputer Applications 3

The Final Product An articulated curriculum that can be used with students entering the workforce, dislocated workers, and incumbent workers; An articulated curriculum that can be used with students entering the workforce, dislocated workers, and incumbent workers; In sequence… In sequence… 350 hour non-credit certificate for which RACC gives 11 academic credit hours; 350 hour non-credit certificate for which RACC gives 11 academic credit hours; Toward a 39 hour academic certificate or a 69 hour Associates degree; Toward a 39 hour academic certificate or a 69 hour Associates degree; Toward a Bachelors degree in Electro-Mechanical Technology from PSU or in Mechatronics Engineering Technology from Purdue University Toward a Bachelors degree in Electro-Mechanical Technology from PSU or in Mechatronics Engineering Technology from Purdue University

Industrial Maintenance / Mechatronics School to Work to School Core CTC Industrial Maintenance Curriculum Available in 8 County Region 1.Employment Practices 2.Safety 3.Introduction to basic electrical skills and circuits 4.Introduction to maintenance principles 5.Introduction to service and repair principles 6.Industrial Electricity 7.Industrial Electronics 8.Troubleshooting and problem solving techniques 9. Automated motors and control systems 10. Introduction to sensors 11. Mechanical power transmission 12. Introduction to fluid power – pneumatics and hydraulics 13. PLC basics 14. Basic principles of refrigeration 15. Introduction to robotics 16. Building wiring installation and maintenance Dept. of Education Sanctioned Core Topics

Industrial Maintenance / Mechatronics School to Work to School NCIST-Based Industrial Maintenance Curriculum Available at Selected CTC’s Core CTC Industrial Maintenance Curriculum Available in 8 County Region 1.Electrical Control Circuits 2.Electrical Motor Control 3.Residential / Commercial Wiring 4.Industrial Wiring 5.Programmable Logic Controllers 6.Hydraulics 7.Hydraulic Troubleshooting 8.Piping Systems 9. Pneumatics 10. Pneumatic Maintenance 11. Electro-fluid Power 12. Electronic Sensors 13. Basic Mechanical Drives 14. Light duty V-belt and Chain Drives 15. Heavy duty V-belt and Chain Drives US Department of Labor Sanctioned – Intermediate Level

Associate of Science in Mechatronics Engineering Technology 69 credits - Available at Reading Area Community College Industrial Maintenance / Mechatronics School to Work to School NCIST-Based Industrial Maintenance Curriculum Available at Selected CTC’s Core CTC Industrial Maintenance Curriculum Available in 8 County Region Core Education Requirements Mechanical / Fluid Power Engineering Technology Electrical / Electronics Engineering Technology Systems / Process Control Engineering Technology Computer Science & Engineering Technology

Bachelor of Science in Electro-Mechanical Engineering Technology 130 Credits - Available at Penn State Berks Associate of Science in Mechatronics Engineering Technology 69 credits - Available at Reading Area Community College Industrial Maintenance Certificate Program 34 credits - Available at Reading Area Community College Industrial Maintenance / Mechatronics School to Work to School NCIST-Based Industrial Maintenance Curriculum Available at Selected CTC’s Core CTC Industrial Maintenance Curriculum Available in 8 County Region CTC student may obtain 11 to 17 college credits through dual enrollment. NCIST Integrated Systems Technologist Certification 200 Hours of Coursework Available via CTC/RACC Dual Enrollment, RACC Classroom / Lab Study, Internet Courseware with Lab at RACC or CTC College credit may be granted for employer sponsored incumbent worker training. 78 Credits transferable from RACC to Penn State

Bachelor of Science in Electro-Mechanical Engineering Technology Associate of Science in Mechatronics Engineering Technology Industrial Maintenance Certificate Program Industrial Maintenance / Mechatronics Target Occupations NCIST-Based Industrial Maintenance Curriculum Available at Selected CTC’s Core CTC Industrial Maintenance Curriculum Available in 8 County Region Systems Engineer Mechatronics Engineer Mechatronics Technician/Designer Maintenance Supervisor Electro-Mechanical Specialist Packaging Machinery Technician/ Designer Maintenance Technician Mechanic Electrician Maintenance Staff

Industrial Maintenance / Mechatronics Incumbent Worker Training University Community College Career & Technology Centers Incumbent Worker Training Programs Customized to Employer Needs Working as a regional educational consortium, courses will be offered by the appropriate institution at the appropriate location for labs and students College credit may be offered through the community college for employer- sponsored training

Industrial Maintenance Training Center 50+ companies have piloted the 350 hour NCIST training; 50+ companies have piloted the 350 hour NCIST training; 250+ employees have been engaged in the training over four years 250+ employees have been engaged in the training over four years Online training for didactic content with laboratory-based skills certification; Online training for didactic content with laboratory-based skills certification; Assessment to give credit for prior learning; Assessment to give credit for prior learning; Funded with over $1 million in grants from the PA Department of Labor and Industry Funded with over $1 million in grants from the PA Department of Labor and Industry

What We Learned Urgent need of important industries; Urgent need of important industries; Demand-driven curriculum design; Demand-driven curriculum design; Schools that listen to what industry tells them; Schools that listen to what industry tells them; Bring to scale (regional project); Bring to scale (regional project); Stage the implementation; Stage the implementation; Evaluation continuously; Evaluation continuously; Bring some funding to the table Bring some funding to the table

Latest Developments Developed the Mid-Atlantic Mechatronics Advisory Committee, a national advisory committee of technology providers and end users; Developed the Mid-Atlantic Mechatronics Advisory Committee, a national advisory committee of technology providers and end users; Awarded and completed a Regional Innovation Grant in packaging; Awarded and completed a Regional Innovation Grant in packaging; Competency model for mechatronics approved by the US Department of Labor puts the skills in a hierarchy that flows from foundation skills to basic manufacturing skills to higher-end technical skills. See the model and the detail behind it at Competency model for mechatronics approved by the US Department of Labor puts the skills in a hierarchy that flows from foundation skills to basic manufacturing skills to higher-end technical skills. See the model and the detail behind it at Skill standards being defined by the Packaging Machinery Manufacturers Institute enumerate more specific standards to guide curriculum development Skill standards being defined by the Packaging Machinery Manufacturers Institute enumerate more specific standards to guide curriculum development

Contact Scott Sheely Executive Director Lancaster County Workforce Investment Board 313 W. Liberty St., Suite 114 Lancaster, PA