virtual cnc training lab story

Virtual CNC Training Lab Story

Liu PeilingTuesday, May 29, 2007

Table of Contents

• Local Enterprise and Association Development Programme (LEAD)– “Industry-led and Government-backed”– Why Industry Associations Should Take the Lead?

• Singapore Precision Engineering & Tooling Association (SPETA)– Role of SPETA in Manpower Development– SPETA Manpower Development Initiatives

• Worldwide Virtual CNC training R&D Situation – AVML & VIRTOOL

• Success Story

Local Enterprise and Association Development Programme

(LEAD)• Some S$50 million has been set aside over three years to

build up a base of able and willing associations to lead in industry development efforts.

• To enhance industry and enterprise competitiveness through partnerships with associations which are willing to take the lead in development and drive initiatives to improve the overall capabilities of SMEs:– Technology & Infrastructure – This will encourage enterprises to

improve their capabilities and productivity by leveraging on enterprise applications and relevant technology infrastructure to innovate and enhance their business operations. It includes the adoption of info-communication technology, development of technical standards and establishment of industry-wide infrastructure

– Intelligence & Research – This will encourage enterprises towards a deeper understanding of industry trends and requirements so as to develop industry specific solutions through comprehensive research based on sound market intelligence

Industry-led and Government-backed• Trade and Industry Minister Lim Hng Kiang, who launched the

programme, said it signalled the government's commitment to working with industry associations to nurture the local industrial landscape.

• Geared at providing focused and customised assistance to the associations at the industry level, it complements the various initiatives already in place for individual enterprises.

• Mr Lim stressed the need for the government to foster even closer partnerships with industry associations.

• And he believed that going forward, Singapore could achieve the next stage of its economic growth if it adopted an "industry-led and government-backed" approach.

• Mr Lim urged the associations to make full use of the LEAD Programme to meet the needs of their members and help their industries move ahead.

• The government, on its part, will work closely with them to help them formulate and implement self-sustaining industry development blueprints.

Why Industry Associations Should Take the Lead?

• The Government designed incentives and assistance programmes to cater to and benefit the individual enterprise. While this approach has served us well, it does not provide enterprises with customised and focused assistance. – At the same time, industries in major economies such as Europe, Japan

and Korea have adopted the model of private sector-led industry development. For example, industry associations in Europe are well-established and have a long history of serving the needs of their members. These associations serve as regulators for specific trade registration and skills certification. Closer to home in Asia, the Japan Electronics and Information Technology Association, or JEITA is another fine example of industry association leadership.

• We can achieve the next stage of our economic growth if we adopt an “Industry-led and Government-backed” approach. For Singapore to become an innovation-driven economy, the private sector needs to play a bigger role. After all, industry associations know private sector businesses best – in terms of the industry’s unique problems and challenges. They can play an instrumental role in the improvement and upgrading of their industries.

Singapore Tooling Industry• Contributed to 6% GDP or 9.3 billion and involved 27% value-added

total manufacturing in year 2002, PE industry is pivotal to the competitiveness of whole manufacturing sector. The output of PE accounted for more than a tenth of total manufacturing output in 2002 and EDB attributed PE as a key growth area and expected to double in output over the next decade.

• When looking inside the PE industry, it can be found that the industry relies strongly on the capability and depth of experience and capacity of CNC machining. As the cutting edge of precision industry, CNC machining produces essential inputs for manufacturing products by providing injection mould, sheet metal die, casting die, jigs and fixtures and other special tools. Creating output of 850 million in year 2001, CNC machining are major component in Singapore industry.

• PE industry is facing rigorous competition from both advanced countries like Germany, US and Japan, and rapid developing regions like Taiwan and mainland China. A survey to local companies done by EDB shows that the skill of Singapore worker lags behind.

History of the Tooling Industry in Singapore

1960 - 1970 Birth of the Singapore tooling industry • EDB set up new training centres, such as the metal industry development centre, prototype production & training centre,

precision engineering development centre, to meet the demands of foreign investors

1970 - 1980 Emergence of the Singapore tooling industry• Government idustrialisation policy was readjusted towards skills-intensive industries, such as Tata Precision Engineering,

Texas Instruments, National Semiconductors, Rollei, HP & General Electric• EDB set up government partnership training centres, such as Tata, Philips and Rollei government training centres, to meet the

demands for skilled workers

1980 - 1990 Growth of the Singapore tooling industry• Government readjusted their policy towards high tech industries• EDB encourages the introduction of advanced equipment, such as CNC machines

1990 - 2000 Upgrading into a regional high tech, high precision and capital intensive• Increased regional costs competition• Shifts towards high tech, high precision and capital intensive industry• Drive towards regionalisation• Gintic merged with IMT / Precision Engineering Application Center (PEAC) • EDB launched many skills upgrading training, such as 3D mould design and CAD/CAM

2000 and beyond Re-inventing to meet the challenges of globalisation• Many knowledge-based and IT-based industries are starting to replace the traditional labour- and skills-intensive industries• Shifts towards high tech, high value added products• Different skill sets, such as knowledge-based and IT skills, implies an emphasis on manpower upgrading

Singapore Precision Engineering & Tooling Association

(SPETA)• SPETA is a non-profit trade association representing

locally registered companies engaged in the manufacturing of moulds & dies, jigs & fixtures, metal stamping, metal castings, plastic and rubber moldings, precision machining, photonic and semi-conductor equipment, aerospace and automotive parts, as well as in providing services related to the precision engineering industry.

• Founded in 1982 as the Singapore Tool & Die Association, it had changed its name to Singapore Precision Engineering & Tooling Association in 1988.

• Provides industry feedback on skills training and curriculum for the Nitec and Diploma courses, e.g.

– development of the part-time “Diploma in Precision Engineering”– Sit on the “Industry Skills and Training Council” that oversee the development of the

‘National Continued Education and Training Framework’ – Focus on the training of strategic manpower to complement the national education and

training system in meeting the manpower needs of the tooling industry• Industry partner in national manpower development programmes, e.g.

– Precision Engineering Manpower Development• a training bursary cum bond scheme to attract foreign students to study precision

engineering courses at ITE and work in the Singapore tooling industry upon graduation

– Precision Engineering Training Award• to encourage local students to take up precision engineering courses at ITE

– Industry Training Award• to encourage local and foreign students to take up precision engineering courses at ITE

Role of SPETA in Manpower Development

Manpower Development Initiatives

• Established the SPETA - 3D CAD/CAM Unit – an initiative heavy funded by the government to drive the application of 3D CAD/CAM

tools in the design and manufacture of precision plastic injection molds• Initiated “Train-and-Place” programmes

– provision of training cum job placements for CNC machinists and CAD/CAM Operators• Program manager for the “Place-and-Train” programme

– a new initiative by the Singapore Workforce Agency, an agency under the Ministry of Manpower, to place local workers in the Singapore tooling industry and provide the necessary skills training

• Developed skills standard, curriculum and courseware for:– CNC Machining (milling, die-sinking and wire-cut) / 3D Mold Design / CAM

• Provided CNC machinist training in:– 3-Axis CNC Milling / Die-sinking / Wire-cut

• Provided specialist upgrading training in:– 3D Mold Design (for mold designers) / CAM (for CAD/CAM practitioners)

Why CNC Training?• So called high tech revolution of precision engineering, represented by

pervasive use of computer such as CNC control, CAM, HSM, ultra machining, not only reduce the dependence of precision engineering on unskilled workers, such as manual polisher, but also create a pool of demand on skilled workers, such as skilled CNC machinists, especially who can operate knowledge intensive HSM and ultra precision machining.

• In today's competitive world, not only the latest technologies are needed, but most importantly, highly-qualified personnel. This is especially true when it comes to working with CNC Machines. Only when CNC machines have been perfectly mastered are high productivity and exceptional quality guaranteed. Skilled workers, especially the machinist who can operate High Speed and Ultra Precision Machine Tool, are playing a key role in current situation.

• HSM requires the machinist to know not only how to operate the machine tool but also machining knowledge, in order to plan a successful cutting. Lacking of skilled worker, especially skilled machinist who can do high speed and ultra precision machining, is a major problem for local industry. Skilled machinists are in high demand in Singapore and Asia, especially in China.

Why Virtual CNC Training?Customizable training software to replace expensive machine

• Presently, trainees acquire their operating skills by observing, referring the operation manual and then operating under the guidance of an experienced operator. The training of skilled machinists is still a slow and manual process, which need a lot of machine tools and fixtures etc. The machining job has a traditional image problem of black smith. To make training safer, more economical and more effective, there is an increasing desire to complete initial training away from the operating environment.

• It is recognized that ITE schools, industrial training centers, public education facilities, machine tool manufacturers and dealers are having increasing-complexity of training requirement. They require not only training software but more comprehensive turnkey solutions for CNC training system.

• Simulation of machining process is helpful to avoid human errors, especially in the training center. Comparing with the sharp decline of the computing cost, worldwide material and machine tool prices are upsurge significantly. Saving material and machine through pervasive application of modeling and simulation (M&S) in CNC training is not only technically possible, but also makes business sense in the current high material and energy cost situation.

Worldwide Virtual CNC R&D

• USA - AVML - Advanced Virtual Manufacturing Lab– Develop a highly realistic virtual manufacturing lab

which includes CNC milling machines and lathes for use in training and research

• EU - VIRTOOL - Virtual Manipulation to Simulate Machine Tool Processes – To develop an educational software tool for the

simulation of common machine Tool operations.

Virtual CNC Applications

• Virtual advanced manufacturing training and education in academia and industry

• Visualization of next generation machine tools

• Virtual product realization and optimization • Virtual factory

National Interest

• A key factor to retaining manufacturing jobs is a highly skilled workforce that can effectively and efficiently use state-of-the-art machine tools

• Most potential manufacturing workers do not have access to state-of-the-art manufacturing labs that can provide such training

• The US President’s Executive Order identifies manufacturing workforce skills improvement technologies as high-priority

Industrial Customer Needs 1

• Increase effectiveness of on the job training – On job training of manufacturing workers is

expensive and time consuming. – Virtual CNC can be used to inexpensively train

workers on advanced machine tools. • The training can encompass conditions that are hard

or expensive to duplicate in the real factory such as effects of raw material shortages, emergency breakdowns, handling of hazardous situations, and unplanned interruptions.

• Training in a risk free environment and without negative impact to production schedules for heavily utilized machinery.

Industrial Customer Needs 2

• Improve design of next generation machine– Customers of next generation machine tools don't get to

use them until after they have been delivered. At that time, it is often too late for modifications. Also, initially it takes a long time for the operators to get the new machine to full productivity.

– Provide visualization of various design alternatives for end users long before the machine tool is made and delivered. This will optimize the configuration and reduce the cost and increase the quality.

– Easily and inexpensively train operators even before the machine's installation, thus greatly accelerating deployment in production and shortening the time it takes to achieve maximum productivity.

Academic and Industrial Customers Joint Needs

• Foster cooperation between academia and local industry – Local colleges and university students are given basic

training on generic and outdated manufacturing equipment that is not directly relevant to local employers.

– Virtual CNC allow local colleges and universities in partnership with local employers to easily and cost effectively develop training on virtual machine tools that are directly relevant to local manufacturing employers.

Summary - Educational Benefits:

• Virtual CNC has broad impacts to the advancement of manufacturing technology and the promotion of creativity and collaboration in manufacturing education and training.

• Due to high cost, there are only a handful of universities that have manufacturing labs that are on the leading edge of technology. This greatly restricts access of both students and researchers to such high-end labs. What is unique about Virtual CNC is that it will allow, for the first time, broad access to advanced manufacturing labs.

• Foster cooperation between academia and local industry in workforce development

• Economic Benefits: – Strengthen manufacturers competitiveness in global

markets and advance important national interests.

• Societal Benefits: – Provide accessibility to education and training on

advanced manufacturing machinery for underrepresented groups and underprivileged sectors of society who would not otherwise have access to an advanced manufacturing lab. Such access will enable those groups to reclaim manufacturing jobs that otherwise would be outsourced overseas.

Virtual CNC Lab Showcase

MTA Daily Show

Virtual CNC Training Lab in ITE

MTA 2007 Industry Night

SPETA's 25th Anniversary

Speech by the Minister of State for Trade and IndustryMr Lee Yi Shyan

at the Showcase of SPETA LEAD Projects

“ SPETA, together with SIMTECH, has developed a simulator for training computer numeric control machinists, which can significantly reduce the hours and machine resources required, compared to traditional training methods. In other words, trainees would be able to practice different and more types of machining requirements within the same allocated training time. With this additional preparation, trainees would have a shorter learning cycle when they start working with the companies. I am pleased to note that the Institute of Technical Education (or ITE) is already in discussion with SPETA to integrate this simulator into their training curriculum.”

Joint Media Release by SPRING and IE Singapore

• SPETA’s initiatives under the industry development plan are already underway. The 180-strong industry association gave an update on their initiatives and showcased some projects at their Annual General Meeting (AGM).

• Minister of State for Trade and Industry, Mr Lee Yi Shyan, who officiated at the event, commended SPETA for championing the development of the PE industry. He urged companies to “differentiate themselves by providing products and services which cannot be easily copied or matched, seek new growth markets, enhance their technical capabilities to move up the value chain, and attract and retain talents and upgrade the skills of their workers.”

• SPETA Chairman Dr Felix Ong said, “We are very happy that our industry plan and efforts have the support of SPRING and IE Singapore. Our PE industry will be poised to meet the new global challenges ahead through the development of new markets and businesses, and upgrading of our capabilities.”


• Singapore’s precision engineering (PE) industry can look forward to creating $475 million more revenue and $150 million in value added – plus 2,000 jobs -- in the next three years. This is all thanks to the $5.6 million investment pumped in to invigorate the sector by the Singapore Precision Engineering and Tooling Association (SPETA) – with support from the government under the Local Enterprise and Association Development programme (LEAD).

• SPETA is among 13 industry associations that have received support under the LEAD programme. Launched in May 2005, LEAD is a multi-agency initiative jointly led by SPRING Singapore and International Enterprise (IE) Singapore to enhance industry and enterprise competitiveness through partnerships with industry associations to improve key capabilities of local enterprises in their sectors.


• SPETA has identified several critical areas to enhance the capabilities of the PE companies. One example is the training of computer numeric control (CNC) machinists, which traditionally requires one machine for one machinist, resulting in heavy capital investment. SPETA, together with SIMTech, developed a simulator for training CNC machinists – somewhat like the flight simulators to train pilots – which will significantly trim the training hours on the actual machine and machine resources required. As a result, the number of students trained is doubled.

• This is the world’s first simulator that uses a three-dimensional precise unified geometrical model and it allows students to simulate the milling process and save the “machined” model for other downstream machining process. The virtual CNC simulator also allows for different situations to be tested during training, which would be costly if done on the machines. The Institute of Technical Education (ITE) is in discussion with SPETA to integrate this simulator into its curriculum.

Media Release by IE Singapore - About Virtual CNC Training Software the world’s first 3D training simulator

• Using the latest modelling and computer technologies, training CNC machinists will never be the same again. Working like a flight simulator that train pilots, this training software will provide realistic training from the setup to the operation of the CNC machines and the simulation of the actual machining process. With this training simulator, students would be able to familiarise themselves with the setup and operation of the CNC machines before practicing on the actual machines, and have a better understanding the machining process using this training simulator.

• This training simulator would be able to help educational institutions enhance the quality of their CNC training courses using scenario-based training and at the same time reduce their capital investment in CNC machines and training consumables, such as raw stock and cutters, by more than 50%.

• This software is developed by SPETA and the Singapore Institute of Manufacturing Technology (SIMTech). This development project is one of the projects supported by SPRING Singapore and IE Singapore under the Local Enterprise and Association Development Programme (LEAD).

• The virtual CNC simulator is the world’s first training simulator that utilises a three-dimensional precise unified geometrical model which allows the students to simulate the milling process and save the ‘machined’ model to be used in the simulation of another downstream machining process. It is also the world’s first CNC training simulator that provides realistic training from the setup to the operation of the CNC milling machine.

• SPETA is in the process of integrating the CNC Mill into its training courseware for CNC machinists. The enhanced CNC machinist training course will also be aligned with the precision engineering workforce skills and qualifications framework (PE-WSQ) developed by the Workforce Development Agency (WDA). The intention of this enhanced training course is to allow the students to practice different and more types of machining requirements within the same allocated training hours, thus reducing their learning curve when they start working with the companies.

Business TimesPrecision engineering industry gets $5.6m boost

AN INVESTMENT of $5.6 million will benefit Singapore's precision engineering industry to the tune of $475 million more in revenue and $150 million more in value-add over the

next three years. An estimated 2,000 new jobs will also be created.

• This was announced yesterday by the Singapore Precision Engineering and Tooling Association (Speta) at a showcase of its latest projects. The investment was made by Speta, with funding from the Local Enterprise and Association Development (Lead) programme.

• The Lead programme is led by Spring Singapore and International Enterprise Singapore. It accepts proposals from industry associations and funds up to 70 per cent of the costs for qualifying projects.

• Speta's proposal was approved in February last year. Their projects include a virtual training laboratory for machinists, which will lower costs and reduce the risk of injury and machine damage.

• The software, currently in the beta stage, was developed by Speta and the Singapore Institute of Manufacturing Technology. It may soon be patented.

• Speaking at the event, Minister of State for Trade and Industry Lee Yi Shyan said: 'Strong industry associations, such as Speta, are the backbone for vibrant industry clusters and, ultimately, a competitive economy.'

Channel NewsAsia SPETA to raise profile of precision engineering firms, expand industry

• Singapore's precision engineering players are banding together to sell themselves overseas and to provide more training for highly-needed skills.

• It is expected that the moves will help the precision engineering industry create 2,000 jobs and generate $475 million more in revenue over the next three years.

• Besides the lack of global exposure, it says the industry is also short of some 500 highly-skilled technical staff in areas like mould design, production and machining.

• The sector is among 13 industry associations which have received support under the government's Local Enterprise and Association Development (LEAD) programme.

• And SPETA plans to use its $5.6 million grant under the scheme to help the sector keep pace with market demands.

938LIVE's Irene Chan reports...• Precision Engineering industry to gain $475m more

revenue • The precision engineering industry is set to create 475

million dollars more revenue and over 2000 new jobs over the next 3 years.

• This is thanks to a 5.6 million dollars investment pumped in by the Singapore Precision Engineering and Tooling Association or SPETA, with support from the government.

• Under the Local Enterprise and Association Development or LEAD programme, SPETA has embarked on several initiatives to enhance the precision engineering industry.

龚慧婷 - 精密工程与模具商向汽车零件业进军 • 一年前，精工业获得协会和“本地企业与协会发展计划”（简称 LEAD ）的 560 万元拨款，在接下来三年里，估计能协助精密工程业，制造超过 2000 份新工作，并取得额外 4 亿 7500 万元的营收和 1 亿 5000 万元的增值。• 有了资金援助，协会最近也开发了“虚拟数控机床模拟系统”，它类似训练飞机师用的机舱模拟器（ flight

simulator) ，主要是用来培训机床操作员。在传统的训练方式下，每一名受训员工，都需要一台机床。新发明因此能协助减少在机床上的投资成本，并缩短员工受训的时间。

Precision Engineering WSQ• 新加坡劳动力发展局推出精密工程技能资格（ Precision

Engineering WSQ ）系统，协助提升员工技能与专业素质，目标是在 5 年内训练 8000 名员工，以应付高端的工作。• 精密工程是制造业中首个参与新技能资格系统的领域，全国 2300多家精密工程公司属下超过 9 万名员工将受惠。• 劳发局副局长盖瑞韦尔说，精密工程是重要的工程技术基础，应用范围几乎涵盖所有制造行业。此外，精密工程是个正在迅速转型的领域，员工也必须与时并进。他说：“很多人对精密工程的旧印象是，工作环境肮脏又老土，其实不然。精密工程正转型为高增值行业，因此我们要重视员工的培训，让他们具备高科技技术能力。”• 精密工程行业技能与培训理事会主席莫壮涛博士认为，推出精密工程技能资格非常适时，因为它不仅让员工能更有效执行高增值和先进的制造程序，从而提高他们的薪金，也加强员工的受雇能力，能够在任何制造领域里发挥所长。莫壮涛博士也是牧野亚洲

（ Makino Asia ）的总裁。他估计，随着精密工程的快速发展，未来的人手需求也将日益增加，每年将制造 2000 个职位空缺

精密工程创新中心设立助中小同业开拓商机 • 新加坡科技研究局 (A*Star) 属下的新加坡制造技术研究院

(SIMTech) 将与新加坡标准、生产力与创新局 (SPRING)合作，在研究院内设立精密工程创新中心 (Centre of Innovation) ，协助我国精密工程业的中小型企业，把握这个蓬勃扩展的领域所带来的商机。• 有了创新中心后，精密工程中小型企业将能够借助新加坡制造技术研究院、以及新加坡科技研究局属下其他研究机构和高等学府的科技知识、研发基础设施，来发展它们的新产品和程序。创新中心今后将成为本地精密工程中小型企业的一站式科技支援中心。• 贸工部政务部长易华仁昨天在为 2007 年亚洲精密工程、工具与金属加工科技展 (MTA ／ Metal Asia)致词时，宣布了精密工程业的以上最新发展。易华仁说，新加坡制造技术研究院一向是制造业，尤其是精密工程业的出色研发合作伙伴，它今后会为创新中心提供所需的科技内容。至于标新局，它将通过政府去年推出的“科技创新计划”为创新中心提供运作资金。

Speech by Mr Lim Hng Kiang, Minister for Trade and Industry at the Local Enterprise and Association Development (LEAD) Programme Forum:

Learning Journey for Associations• It gives me great pleasure to be here with you at this Local Enterprise

and Association Development or LEAD Programme Forum. LEAD was launched in 2005 with the aim of accelerating the build-up of a strong base of industry associations to lead industry development efforts. Industry associations are well placed to identify the industries’ unique problems and challenges. Through their outreach to members, the associations can play an instrumental role in nurturing and strengthening their industries.

• ……• The Singapore Precision Engineering and Tools Association

(SPETA), for instance, has leveraged on LEAD to embark on a new technology platform called the Computerised Numerical Control (CNC) virtual training laboratory. The new training facility will launch three specialised courseware, ranging from CNC milling to CNC turning and mould design, over the next one year to equip our precision engineering enterprises with niche capabilities.