FEATURE ARTICLE: EDM Technical Training at Macomb Community College
Many who know him would say that Professor Gary Walters is a man of action. And action is just what happened when Gary was presented with the challenge of reviving the 25-year-old Advanced Manufacturing Program at Macomb Community College in Warren, Michigan. Due to dwindling enrollment and out-of-date equipment, Macomb was on the verge of discontinuing the program three years ago. However the efforts of Walters led to a partnership between Macomb and Haas Automation. This partnership ultimately resulted in the creation of the Haas Technical Education Center, located on the grounds of Macomb Community College. The new equipment brought about the ability to create a revised educational curriculum more applicable to the business environment facing manufacturers today. Walters took advantage of the demonstrations being conducted at the education center and used these to implement the program as it currently exists.
The program at Macomb Community College is one of but a few located within the United States. The college offers an accredited EDM training curriculum in addition to the other facets of manufacturing. These include CNC machining, CAD / CAM, rapid prototyping and reverse engineering. Students attending the program earn a certificate as a CNC machinist or CAM technologist. Upon successful completion of the two-year program, students earn an associates degree in applied science manufacturing technology. The program recently added the option of earning a bachelor’s degree in manufacturing, with additional coursework provided through an association with local universities.
In addition to the academic experience through Macomb, students can also enroll in apprenticeships at local shops to get a “real world” experience.
During its short tenure under the direction of Walters, the enrollment surged to as many as 150 students in the program at one time. While about half of the students are recent high school graduates, Walters nicknamed the other half as “upgraders” – machinists with 10-20 years of experience who enrolled into the program looking to hone their skills toward the more advanced technologies available today.
This advanced technology is what caused Gary to turn to Poco Graphite Inc. for advice in the EDM Application segment of the program. Gary knew POCO has conducted extensive research in EDM operations and materials technology. “I’ve always known of the name POCO as the leader in the graphite business,” Walters said, “In fact, I didn’t know anybody else existed.” Walters contacted POCO when he began developing the curriculum for the training. “To my surprise, they responded and sent me their training manual and technical reference guides. They offered me all sorts of help and assistance,” Walters said. Gary is now using POCO’s EDM Technical Manual as one of the textbooks for the EDM training in the program. POCO supplies 20-30 EDM technical manuals to Macomb, free of charge, at the beginning of each term. Professor Walters commented, “I like using POCO’s technical manual in our training because they are one of the world leaders in the EDM process and the manuals are applicable for all brands of EDM sinkers. The manual is a very comprehensive technical publication with hundreds of man hours of testing. We use the manual to properly program our EDM sinker.”
Recently, POCO’s EDM Applications Specialist Jerry Mercer traveled to the college to speak with the students and review the training curriculum. Mercer says, “I was truly impressed with the training Mr. Walters offers and the operations he has within his facility. With his technical background, the knowledge Gary shares with his students better prepares them for employment in a very critical and technical field.” Mercer continues, “POCO has developed an extensive body of knowledge relating to EDM, and we are glad to share it to support the educational programs throughout the United States.” The training provided by Mr. Walters not only shows his students the proper techniques of EDM applications, but he is also teaching the cost advantages and economics of using the right material for the right application. “When an EDM application is being developed, the electrode material must be taken into account and will often show that the true cost savings come with the use of a premium electrode material,” Mercer says. “POCO has plenty of expertise to share, not because we are known as a manufacturer of superior EDM graphite for electrodes but because POCO has built a solid reputation as a provider of EDM performance solutions.”
Not only do the students at Macomb Community work hard in their academics, they also have fun with the machinery. For instance, there is the summer “Art to Part” academy where students design and manufacture components for RC race cars. Students make CNC-machined aluminum racing wheels and vacuum-formed plastic bodies, assemble them and race on the final afternoon in the week-long event. This is just plain fun with the purpose of preparing the students to make it in the competitive manufacturing industry.
“To be employable in southeastern Michigan, a place where thousands of jobs were lost to foreign competition, employees must be both sharp and versatile,” said Walters. “The days of one man to one machine are gone. Workers in a manufacturing setting must program, set up, and operate and monitor multiple machines and processes.”
“Efficiency and flexibility are essential to compete in today’s global economy,” said Walters. “Manufacturing companies using these technologies are in a more favorable position to expand and thrive. We’re helping prepare the people they need to do that.”
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