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Institute for Advanced Learning and Research

Driving Economic Transformation

Inside IALR Podcast: DCC & IALR: A Strategic Partnership

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Inside IALR Podcast: DCC & IALR: A Strategic Partnership

Inside IALR Podcast: DCC & IALR: A Strategic Partnership

“These are really thought-out partnerships, collaborations. We try to maximize all of our resources…DCC is a friend of the Institute along with the other high ed centers…” – Dr. Jerry Wallace, President of Danville Community College

The “Inside IALR” team is joined by two energetic leaders, Danville Community College President Dr. Jerry Wallace and IALR President Telly Tucker. In their conversation, they discuss the strategic, diverse partnership between DCC and IALR, how each organization enhances each other’s work and the critical roles that we play in economic development initiatives, workforce training and more in Southern Virginia.

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U.S. Navy breaks ground on new Regional Training Center (RTC) at IALR Campus

U.S. Navy breaks ground on new Regional Training Center (RTC) at IALR Campus

The new center will accommodate full-scale growth of the defense manufacturing training program, providing a pipeline of 800-1,000 skilled workers per year for high-demand jobs.  

The United States Navy broke ground on a new regional training center for the Accelerated Training in Defense Manufacturing (ATDM) program in Danville today. The new 100,000-square-foot training facility, located on the campus of the Institute for Advanced Learning and Research (IALR), will allow more students to enroll in accelerated four-month training programs to help them reskill or upskill for high-paying jobs. Estimated to open by 2025, the Regional Training Center expects to graduate 800-1,000 students per year to fill critical vacancies across the defense industrial base.

The groundbreaking ceremony was held during the annual ATDM & U.S. Navy Additive Manufacturing Center of Excellence (AM CoE) Summit, which gathered the Navy, Office of the Secretary of Defense, state and local officials, and industry partners to increase awareness of these important initiatives and promote participation and contributions by industry and other stakeholders. This year, ATDM instructors and students were joined by Secretary of the U.S. Navy Carlos Del Toro and Rear Admiral Scott W. Pappano to celebrate the success of the past year and discuss goals going forward.

“The incredible progress made over the past year here in Danville, both in building the next generation of submarine builders at ATDM and in advancing the manufacturing technology we need to succeed at AM CoE, proved that we are on the right path. This past year established the foundation for the critical leaps forward we need in the coming years to scale both programs to ensure we have the skilled workforce with the technology and capabilities needed to build the Navy’s next generation of submarines.” — Rear Adm. Pappano, program executive officer, Strategic Submarines, U.S. Navy

“The groundbreaking of the Regional Training Center is a key milestone in scaling ATDM by providing a dedicated training facility with the infrastructure and equipment necessary to reach our full capacity of training potential,” said Dr. Debra Holley, director of the ATDM program.

Darrell Dalton, Chair of the Pittsylvania County Board of Supervisors, remarked that the construction of the Regional Training Center is a “win for our local economy, as it will bring up to 1,000 students a year to Danville and Pittsylvania County, and all of whom will live, work, and play here. By building its training facility in Danville, the Navy has provided a capital investment that further shows the growing prominence of this region in manufacturing and related industry sectors.”

ATDM Summit 2023

“We are especially fortunate that the Navy has recognized the forethought of our local leaders who have worked over the years to create educational programs that emphasize the type of knowledge and skills needed for this program,” Dalton continued.

In partnership with the Industrial Base Analysis and Sustainment Program Office (IBAS) in the Office of the Secretary of Defense (OSD) and the Navy’s Program Executive Office (PEO) Strategic Submarines, ATDM trains workers in critical manufacturing skills to establish a steady and sustainable flow of workers into the SIB/DIB to fill critical skills gaps and labor shortages. The AM CoE directly supports the growth of our nation’s industrial base by using additive manufacturing for the production of submarine components to bolster naval shipbuilding and repair supply chains.

America’s defense industrial base (DIB) is still greatly in need of workers who can build and repair naval ships. The lack of workforce and manufacturing shortfalls in this area impact the material readiness of the current naval fleet; major maintenance and overhaul availability; and new construction. The construction of the “1 COLUMBIA + 2 VIRGINIA” naval ships beginning in FY26 will further stress the Submarine Industrial Base (SIB) and increase the need for qualified talent in the workforce. The AM CoE, which formally opened at last year’s summit, directly supports growth of our nation’s industrial base by scaling and maturing additive manufacturing technologies in the SIB. The technologies enable innovative production of submarine components to bolster naval shipbuilding and repair supply chains. As a result, the AM CoE will increase overall manufacturing capacity and close the supply-demand gap in critical marketspaces like castings, forgings, fittings, and fasteners.

Secretary of the U.S. Navy Carlos Del Toro (right) and Rear Admiral Scott W. Pappano (left) sign a steel beam that will be part of the new ATDM Regional Training Center.

The Institute for Advanced Learning and Research (IALR) has also been selected by the U.S. Navy Program Executive Office, Strategic Submarines (PEO SSBN) as the designated memorial location for the Ex-USS Buffalo (SSN 715) sail and the Ex-USS Providence (SSN 719) rudder to preserve and commemorate the history of these submarines and honor the service of their crews. This memorial demonstrates the strong partnership between the Navy and Accelerated Training in Defense Manufacturing (ATDM).

“Today marks a new chapter in the exciting growth of the ATDM program and further exemplifies the educational, workforce, and technological innovation that is taking place in Virginia. The investments made here are vital to the economic progress of the entire commonwealth,” said Telly Tucker, president of the Institute for Advanced Learning and Research, which leads the multi-year ATDM pilot project. IALR’s Center for Manufacturing Advancement is also home to the Navy’s AM CoE.

“The ATDM program marks a bold step forward,” said Danville City Councilman Lee Vogler. “This initiative stands at the forefront of addressing the challenges facing our defense industrial base and, by extension, our nation’s security.”

The sail was part of the Ex-USS Buffalo (SSN 715), a decommissioned United States Navy LOS ANGELES Class nuclear-powered attack submarine. USS Buffalo (SSN 715) was commissioned in November 1983, and decommissioned in January 2019. During that time, she saw most of her service in the Pacific area of operation.

The rudder hails from Ex-USS Providence (SSN 719), also a decommissioned United States Navy LOS ANGELES Class nuclear-powered attack submarine. Ex-USS Providence (SSN 719) was commissioned in July 1985. In August 2021, USS Providence was transferred from Naval Submarine Base New London in Groton, Conn., to Kitsap Naval Base in Bremerton, Wash., for decommissioning after 37 years of service.

To learn more about the new regional training center, or ATDM program classes and cohorts, please visit www.atdm.org.

About ATDM

Accelerated Training in Defense Manufacturing is a prototype training platform for rapidly training skilled workers in key trades such as CNC machining and welding for employment in the defense industry. ATDM was developed as a public-private consortium between the DoD, the Institute for Advanced Learning and Research (IALR), Danville Community College (DCC), Phillips Corporation, and The Spectrum Group in consultation with the defense industry. IALR is leading a multi-year pilot project to test and evaluate ATDM as a training platform for regional training centers supporting the defense industrial base. The pilot project is funded through the National Imperative for Industrial Skills initiative, which was launched in 2020 by the Industrial Base Analysis and Sustainment Program Office (IBAS) in the office of the Undersecretary of Defense for Acquisition and Sustainment.

About IALR

The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation through applied research, advanced learning, manufacturing advancement, conference center services, and economic development efforts. IALR’s major footprint focuses within Southern Virginia, including the counties of Patrick, Henry, Franklin, Pittsylvania, Halifax, and Mecklenburg, along with the cities of Martinsville and Danville. For more information, visit www.ialr.org.

“Automagic:” Robots and Automated Manufacturing

“Automagic:” Robots and Automated Manufacturing

Three robots and two large manufacturing machines communicating, collaborating and accomplishing tasks, all without human direction or involvement. Together, they take a piece of aluminum and, through several processes, convert it into a finished and packaged product.

It sounds like something out of a science fiction movie.

However, it will soon be a reality as part of the Industry 4.0 Lab in the Institute for Advanced Learning and Research’s (IALR) Center for Manufacturing Advancement (CMA). IALR staffers have designed and are building an autonomous manufacturing work cell where robots and manufacturing machines communicate via wireless signals. The work cell should be fully operational around December.

With the ability to tweak the process for different scenarios, this Industry 4.0 Lab will serve as a demonstration site, showing manufacturing companies what is possible. Enclosed in a glass room, the Industry 4.0 Lab will also be visible during tours of IALR.

“It’s a demonstration lab to show local industries what new technologies are out there and what might be able to benefit them,” said Butch Kendrick, Director of Digital Manufacturing IALR “We call it automagic.”

Robots and Machines Communicating, Working Together and Directing Each Other

Throughout the automated process, three robots and two different computer numerical controlled (CNC) machines will communicate with each other about the process and what each one needs from the others. All these communications – and the requests and information they share – have been pre-programmed and are managed by a software called a manufacturing execution system (MES).

With no name yet, this robot has one job: tend operations of the CNC machines using its compound gripper.

An autonomous mobile robot (AMR), Ralph consists of a mobile robotic cart and a universal robotic arm with seven joints.

Rosie completes the final inspection of finished products before packaging and preparing them for shipment.

“The actual machines are integrated with the robots,” Yeatts explained. “The machine calls when it needs to be tended by the mobile robot. The only human interaction was the programming. No one’s actually guiding the robot. The robots know the process and complete their jobs as needed.”

There will be alternative steps and workflows depending on the application, but the basic process will go something like this:

  • Under orders from the MES, the tending robot will pick up and load a piece of aluminum into the first CNC machine. With the material firmly in place, the machine will cut a shape. The robot will then take the part out of the machine and place it on a table.
  • Under a request from the tending robot, Ralph will retrieve the part and conduct pre-established inspections with engravers and scanners on the inspection island.
  • After the inspections, Ralph will drive to the CNC milling machine. Ralph will be responsible for tending the machine, putting the part inside and telling the machine to begin the operation before leaving to complete another task.
  • Once complete, Ralph will retrieve the part and take it to the coordinate measuring machine or back to the inspection table, depending on the predetermined workflow. Those that fail inspections or tests at either location would go onto a rejection conveyer belt – an event that would trigger a text or email notification to a human supervisor.
  • If it passes all relevant tests, Ralph will bring the module to Rosie – who received that name after a recent Facebook naming contest. Rosie will complete a final inspection, package the part and set it on a conveyor belt.
  • When Rosie says she has completed her task, Ralph will collect the packaged product and place it in the retrieval area.

The Challenge of an Autonomous Mobile Robot

Two primary challenges came with creating this type of integrated, automated manufacturing workflow.

How precise could the autonomous mobile robot be?

Disbelief and doubt. That is what Kendrick heard from organizations around the country while presenting the idea of an autonomous mobile robot as part of an automated manufacturing process. They said the robot would not be able to leave one post, go to another and then return to the exact same spot.

Butch Kendrick, Director of Digital Manufacturing, works with one of the robots in the Industry 4.0 Lab in the Center for Manufacturing Advancement.

Precision and repeatability are critical in these processes. The cart holding the automated robotic arm must pull up to the exact location every time. The robot arm must be able to reach the exact same spot in space repeatedly.

Kendrick and the Manufacturing Advancement team have developed a robot with extreme locational, three-dimensional precision. Prior to occupying the new CMA, they repeatedly demonstrated this concept in the Gene Haas Center for Integrated Machining, which houses the Integrated Machining Technology program. Once the AMR identifies a point in space and selects it as a reference point, it can return to almost that exact location even after traveling around the room to complete other tasks.

(The robot always came within 0.0015 inches of the point in space. That’s slightly larger than the diameter of a human hair.)

How could each of the robots and machines involved effectively communicate with each other?

What makes this workflow unique is how all the machines and robots communicate with each other through the MES in real time. Throughout the development of a single widget in this workflow, dozens of messages flow between the machines and robots. Some of the examples of messages the robots and machines share:

  • “I’m done with this process. Now you can collect this part.”
  • “The widget is positioned correctly. You can close the door and begin the operation now.”
  • “I am ready to complete another process.”

Traditionally, robots and machines that communicate with each other write files of information and put them in mutually accessible folders. This also requires extensive hardwiring and infrastructure.

“Working in the industry for 35+ years, one thing that disappointed me was working with automation. You had these two pieces of equipment that needed to exchange control information, but it was done in a very archaic way. It was done with technology used in the 1960s and 1970s. I knew there had to be a better way.” – Butch Kendrick, Director of Digital Manufacturing, IALR 

But what if that communication could happen in real time? Each machine and robot has its own language. The key to allowing real-time communication, Kendrick said, has been creating proper protocols, which function as a sort of universal language between the technology and the MES. One of the focus areas of Industry 4.0 is creating the ability for different machines to communicate wirelessly without delay, which creates flexibility and reliability.

The Impact on Southern Virginia and Beyond

The Industry 4.0 Lab fits into the overarching mission of the CMA: to serve as the destination of choice for innovative manufacturers ready to optimize their operations and scale and facilitate the expansion of the advanced manufacturing sector. But the interplay between robots, machines and manufacturing processes is just one of the appeals of the CMA. Other features include:

  • Rapid-launch high bays can provide a temporary home for companies developing their own facility, expediting operational start-up time.
  • A CNC machining innovation lab enables new and existing businesses to evaluate their processes, build out improvements and incorporate efficiencies.
  • An ISO-certified metrology lab provides the integrated inspection capabilities required to validate product quality and includes one of the largest coordinate measuring machines on the East Coast.

The CMA is positioned next to the future Regional Training Center for the Accelerated Training in Defense Manufacturing program and other manufacturing training programs from IALR and Danville Community College. With the potential to host some classes and have students learn robotics and automation in the Industry 4.0 Lab, the CMA will also help prepare the workforce for advanced manufacturing jobs.

“Even with the rapid development of automation and technology, manufacturing jobs are not going anywhere. They are simply evolving to require more skills in areas like coding, engineering and math. Much of our focus at IALR is preparing the workforce for the future by teaching those needed skills in programs across all age and experience levels.” – Todd Yeatts, Executive Vice President, Manufacturing Advancement, IALR

The Center for Manufacturing Advancement provides state-of-the-art facility space, technology and equipment as well as leading expertise to position Southern Virginia as the destination of choice for advanced manufacturers.

Both existing manufacturers in the region looking to expand and manufacturers looking to enter Southern Virginia with a new site location are already benefiting. The United States Navy also established its Additive Manufacturing Center of Excellence (AM CoE) within the facility. The AM CoE will develop manufacturing “recipes” (technical data packages) that other organizations around the country can utilize to create parts and components. Several industrial manufacturing partners located in Southern Virginia for the first time due to the AM CoE.

“Today’s manufacturing and workforce challenges require comprehensive and innovative approaches to the way industry collaborates, along with significant investments in infrastructure, equipment and people. The CMA fosters each of these obligations in a way that will benefit the region, the Commonwealth and the country.” – IALR President Telly Tucker

These goals will remain the same in the Industry 4.0 Lab and the entire CMA, even as the equipment and processes evolve.

“I’m hoping everybody will be using this technology, this equipment and these processes five years from now,” Kendrick said. “Integrated automation and robotics will be commonplace, and our team will be looking at newer technologies and processes.”

Linda Green of IALR Wins Women in Leadership Award

Linda Green of IALR Wins Women in Leadership Award

Linda Green, Vice President of Economic Development at the Institute for Advanced Learning and Research (IALR), joins 36 other executives as one of the winners of this year’s Virginia Business Women in Leadership Awards.  

Green has served in her current role as well as the Executive Director of the Southern Virginia Regional Alliance (SVRA) since 2016. As Virginia Business states, since that time, she has “worked in collaboration with economic developers to recruit 28 new companies to Southern Virginia and assist the expansion of 31 existing companies.” Virginia Business goes on to share that “Green says these efforts have created more than 5,300 jobs and spurred about $1.5 billion in capital investment across the region.”

“We are extremely fortunate to benefit from the keen economic development expertise of one of the state’s leading professionals in this area,” said Telly Tucker, President, IALR. “Linda’s love for Southern Virginia and her tireless efforts to contribute toward the growth and transformation of the region are evident and well respected by local, regional and state stakeholders across multiple industries and span both the public and private sectors.” 

Prior to her role at IALR and SVRA, Green worked as District Director for U.S. Congressman Robert Hurt and as Director for Federal Funding and Entrepreneurship for the Center for Innovative Technology, where she also served terms as Director of Manufacturing and Regional Technology Transfer. She also served as the President and CEO of the Dan River Business Development Center and worked as a Quality Engineer for Goodyear Tire and Rubber Company. A Certified Quality Engineer, Linda holds a Master of Business Administration from Duke University and is a graduate of Averett University and Danville Community College. 

“I am thrilled to be recognized for this esteemed award and appreciate Virginia Business’ commitment to honor and support the leading role that women play in the many businesses and industries across our Commonwealth,” said Green. “I also acknowledge the importance of working with a collaborative team of professionals who welcome and support female employees and cohorts — helping one another succeed is a blessing.”  

Virginia Business editors selected awardees from more than 320 nominations submitted by readers. According to the media outlet, “editorial staff considered factors such as overall professional accomplishments, civic engagement, mentoring and breaking glass ceilings.”   

The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation with applied research, advanced learning, manufacturing advancement, conference center services and economic development efforts. IALR’s major footprint focuses within Southern Virginia, including the counties of Patrick, Henry, Franklin, Pittsylvania, Halifax and Mecklenburg along with the cities of Martinsville and Danville. 

IALR Announces New EVP of Operations

IALR Announces New EVP of Operations

The Institute for Advanced Learning and Research (IALR) is pleased to announce Dr. John H. Hughes IV as Executive Vice President, Operations, effective June 1. Most recently serving as the Assistant City Manager for Lynchburg, Va., Hughes brings nearly two decades of experience in government operations, administration and service. He will serve as the chief business and operations officer and will report directly to IALR President Telly D. Tucker.  

“I am thrilled to welcome Dr. Hughes to the Institute for Advanced Learning and Research team,” said Tucker. “As we continue to position Southern Virginia as a destination where all can live and thrive, I am confident Dr. Hughes’ leadership background, operations experience and creative approach to community building will help us ensure the exceptional quality and operational excellence our communities and employees deserve.” 

Dr. John H. Hughes IV is IALR’s Executive Vice President, Operations, effective June 1

Having previous experience with workforce training, continuing education, human services and more, Hughes is fascinated by IALR’s mission to catalyze regional economic transformation. 

“I am humbled and inspired to join a progressive and innovative organization focused on revolutionizing the economic landscape of Southern Virginia,” Hughes said. “With its state-of-the-art facilities, innovative programs and dynamic people, IALR positively influences Southern Virginia and beyond. I look forward to contributing to that mission of continued, tangible impact.” 

Hughes will serve as the chief business and contractual liaison for IALR operational matters with IALR partners. One of his primary responsibilities will be leading the functions organized within IALR’s business and operations departments, including Communications, Technology, Facilities and the Institute Conference Center as well as Applied Research. Hughes will focus on aligning IALR’s administrative systems, policies, structure and procedures to the organization’s five-year strategic plan. He will also focus on developing leadership in a rapidly growing organization to ensure continuity and sustainability into the future. 

While serving as the Assistant City Manager for Lynchburg, Hughes spearheaded a collaborative, impactful poverty-reduction effort through public-private partnerships, grants, workforce development and soft-skill development, continuing education and job placement programs – all focuses of IALR. Hughes also supervised several departments, including Human Services, the Lynchburg Public Library and Department of Parks and Recreation. Hughes previously worked as a Foster Care Social Worker and Senior Family Services Specialist before spending nearly a decade as the Children’s Services Act Coordinator for the City of Lynchburg.  

A native of Lynchburg, Hughes supported the local community via several volunteer and appointed boards including the Greater Lynchburg Transit Company, Lynchburg Community Policing Advisory Committee, Martin Luther King Jr. Lynchburg Community Council, Hill City Youth Football & Cheerleading, Mary Bethune Academy, Southern Memorial Association (Old City Cemetery), Juvenile Justice Advisory Board, Community Criminal Justice Board, Action for Change Committee, Virginia Center for Inclusive Communities and the Central Virginia Continuum of Care.  

Hughes has been active with professional and civic organizations including the Virginia Local Government Management Association, the National Forum for Black Public Administrators and the International City/County Management Association. He is a member of the Omega Psi Phi Fraternity Inc. 

Hughes earned a Master of Business Administration in 2009 and obtained his doctorate in education from the University of Lynchburg (formerly known as Lynchburg College) in 2023. Hughes also holds two bachelor’s degrees – one in social science, the other in business administration – from the University of Lynchburg.   

The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation through applied research, advanced learning, manufacturing advancement, conference center services and economic development efforts. IALR’s major footprint focuses within Southern Virginia, including the counties of Patrick, Henry, Franklin, Pittsylvania, Halifax and Mecklenburg along with the cities of Martinsville and Danville. For more information, visit www.ialr.org.