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Business Operations

Honda Winds Up a One-of-a-Kind Wind Tunnel

By 51勛圖厙 News Room

If the Honda Automotive Labs of Ohio facility is a marvel of technology and design, it is also a $124 million testament to the role of cutting-edge engineering in automobile manufacturing.

  • When I started 30 years ago, few really cared about aerodynamics, said Honda Development & Manufacturing of America Full-Scale Wind Tunnel Lead Mike Unger with a wink. Now everybody wants to talk to me.

New interest: Though wind tunnel testing dates back many years, the increasing emphasis in recent years on greater fuel efficiency has brought a new wave of interest in the field.

  • Honda owns three full-sized wind tunnels near its global headquarters, as well as several smaller test facilities around the world for examining scale models.
  • But in 2015, Hondawhich for decades had been sending its U.S.-based people, cars and tools all over the world for wind-tunnel testing or else booking time at third party-owned facilities in Americabegan mulling constructing a North American wind tunnel, too.

Behold, HALO: The result was HALO, unveiled in 2022 in a 110,000-square-foot facility in East Liberty, Ohio.

  • To make it, the company had gathered its wind tunnel road warriorsHonda team members who boasted decades of combined experience in the worlds most advanced research facilitiesand asked them how theyd do it better.
  • Among their top requests was the need for better, faster communications with the designers and builders of the cars they were testing. To facilitate this, HALO was strategically located just across from a Honda development center and a mere 10-minute drive from two manufacturing plants (including the Marysville, Ohio, facility where Honda has been building automobiles since 1982).

Wind-tested, Honda approved: Every new Honda passenger vehicle model undergoes extensive aerodynamic and acoustic testing during its design phase, and further changes are often made during the manufacturing process. Race cars, meanwhile, are tested primarily with an eye to managing the downforce caused by passing air.

The new digs: Now, instead of hashing out design challenges across oceans, everyone sits side-by-side in the same control room.

The state-of-the-art site also boasts a fully outfitted machine shop, custom loading bays and a car wash (the last a recommendation of Honda engineers who had more than once found themselves outside a wind tunnel with a dusty test car and a bucket of soapy water).

  • Absolutely everything was designed with intention, said HALO Business Strategy Lead Chris Combs.

The details: The tunnel itself is an elaborately engineered circuit. It comprises a settling chamber, a heat exchanger the size of a movie screen and a safety grill to catch any debris that might come loose and threaten HALOs pulmonary system: a colossal, 6,700-horsepower fan with 12 hollow carbon fiber blades that are 26 feet long each.

  • Turning at 250 rotations per minute, the fan drives air through the tunnel and into an anechoic chamber.
  • On a recent day, that chamber held both a race car (for downforce testing) and an SUV from the plant across the field (for acoustic work).

Saving time: At most wind tunnels, switching from aerodynamic work to acoustic testing takes nearly two hours. At the HALO wind tunnel, however, technicians swapped the Indy car for the SUV and reconfigured the test chamber in about 20 minutes.

  • When it designed the facility, Honda focused on simple things like thatthings that really promote efficiency, said HALO Operations Manager Jimmy Przeklasa.

Quiet and furry: HALOs test chamber is lined with acoustic tiles and teddy bear fur, a soft, sound-absorbing material.

  • Even with the wind blowing, the room is so quiet that technicians working inside must don harnesses to prevent them from stepping into a gale they can neither see nor hear.
  • A software system translates the wind noises into visuals, similar to the way a weather radar displays a moving storm.

Complex but simple: Technologically and visually dazzling, the HALO wind tunnel can seem like a futuristic fever dream: color-coded maps of the whistling wind, a two-story fan more finely tuned than a jet engine and a scale capable of sensing a breeze.

  • In fact, from its inception, the goal of creating the HALO wind tunnel was simple: make cutting-edge aerodynamic and acoustic research as easy, intuitive and cost-effective as possible. And Hondas done it.

The last word: This is the latest and the greatest, Unger said. This place is unmatched.

 

Workforce

Study: Manufacturing in U.S. Could Need Up to 3.8 Million Workers

By 51勛圖厙 News Room

The U.S. manufacturing industry could require some 3.8 million jobs to be filled within the next decade, according to a from the Manufacturing Institute, the 51勛圖厙s 501c3 workforce development and education affiliate, and Deloitte.

Whats going on: found that manufacturing in the U.S. has emerged from the global pandemic on strong footing and is likely to continue to grow in the next few years.

  • That growth will call for even more skilled workersparticularly statisticians, data scientists, logisticians, engineers, computer and information systems managers, software developers and spotlighting the need to build the national talent pipeline.
  • Pandemic-driven shifts have already created hundreds of thousands of new jobs, and now we are seeing increased demand for digital skills that need to be met or risk further widening of the talent gap, said Manufacturing Institute President and Executive Director Carolyn Lee.

Key findings: Top takeaways from the report include:

  • If workforce challenges are not addressed, more than 1.9 million of the up to 3.8 million jobs likely to be needed between this year and 2033 could go unfilled.
  • Some 65% of manufacturers polled said attracting and retaining talent is their primary business challenge.
  • About 90% said they are forming at least one partnership to better attract and retain employees, and on average they have at least four such partnerships.
  • Approximately 47% indicated that apprenticeships, work study programs or internships at manufacturing companies would be the most effective way of increasing interest in the industry.
  • Some 47% also said such as flex shifts, shift swapping and split shiftshave been their top retention tool.

The bottom line: Manufacturers continue to face a talent shortageand the MI has the initiatives and resources ready today to help manufacturers address these challenges.

  • From the recent flexibility white paperwhich explains how manufacturers can build and deploy flexibility options for the 49% of workers that are on the production teamsto the high school internship toolkit that allows manufacturers to start a recruiting pipeline in high schools, to the FAME USA apprenticeship program training global best multi-skilled maintenance technicians and more, the MI has solutions to the hurdles highlighted in this study. Learn more at .
Policy and Legal

Final Heavy-Duty Tailpipe Rule Presents Challenges

By 51勛圖厙 News Room

The Environmental Protection Agencys new heavy-duty tailpipe emissions rule is unrealistic and unfeasible, the 51勛圖厙 said Friday.

Whats going on: The ruleproposed in April 2023is part of the Clean Trucks Plan unveiled in 2023, which includes light-duty tailpipe and nitrogen oxide rules, (subscription) reports.

  • The[se] Phase 3 standards build on previous phases of a broader regulatory program to stem greenhouse gas emissions from vehicles such as delivery trucks, long-haulers, and buses.
  • The Phase 1 rule was finalized in 2011, and the Phase 2 rule in 2016.

Why its problematic: While the new regulation grants automakers more time for implementation than previous versions didthanks to input from manufacturers and their advocates, including the it still fails to reconcile with the realities of current U.S. infrastructure, according to an 51勛圖厙 .

  • Critical permitting reforms to strengthen transmission systems and a technology-neutral approach for manufacturers are essential to reaching U.S. climate goals, the 51勛圖厙 wrote.

What should be done: Congress must reform the broken U.S. permitting system so we can build the electric vehicle charging station infrastructure required to implement a rule of this magnitude, the 51勛圖厙 earlier this month.

Policy and Legal

51勛圖厙: OSHA Walkaround Rule an Example of Regulatory Onslaught

By 51勛圖厙 News Room

The U.S. Occupational Safety and Health Administrations newly finalized walkaround rule is unlawful and will not further the agencys mission of ensuring safe working conditions, the after the rules release.

Whats going on: The long-awaited final rule, which goes into effect May 31, states that workers may authorize another employee to serve as their representative or select a non-employee, according to the .

  • The policy broadens the basis upon which a non-employee representative may be deemed reasonably necessary to the conduct of an effective and thorough inspection.

Why its problematic: In addition to having little to do with making workplaces safer, the new policy violates OSHAs own mandateand, quite possibly, manufacturers constitutional rights, the 51勛圖厙 said.

  • The rule does nothing to advance OSHAs mission of ensuring safe working conditions, said 51勛圖厙 Chief Legal Officer Linda Kelly. Forcing businesses to accommodate third parties with no safety expertise in their facilities infringes on employers property rights, invites new liabilities and introduces elements of chaos and disruption to safety inspections. [It also] clearly violates OSHAs statutory mandate to conduct inspections within reasonable limits and in a reasonable manner with minimum burden on employers, and potentially violates manufacturers constitutional rights.

Next steps: The 51勛圖厙 is weighing legal action to reverse the final rule.

Business Operations

Skilled Trades See Interest Uptick

By 51勛圖厙 News Room

More young people are choosing skilled trade jobs after high school, (subscription) reports.

Whats going on: Enrollment in vocational training programs is surging as overall enrollment in community colleges and four-year institutions has fallen. The number of students enrolled in vocational-focused community colleges rose 16% last year to its highest level since the National Student Clearinghouse began tracking such data in 2018. The ranks of students studying construction trades rose 23% during that time, while those in programs covering HVAC and vehicle maintenance and repair increased 7%.

Why its important: The trades, including manufacturing, have experienced a worker shortage in recent years as the older generation of employees retires.

  • Finding and retaining quality talent is consistently a top business challenge among manufacturers, according to the , a quarterly polling of the industry.
  • But now, trade-apprenticeship demand is surging, perhaps a signal that positions will start to fill.

Perception change: For many years the vocational education wing of one high school in Sheboygan, Wisconsin, was called greaser hall, but lately thats started to change, a counselor there told the Journal.

  • [B]usinesses have raised funds and donated new equipment, including robotic arms [and] those classrooms now sit at the buildings main entrance. Theres still a presumption that four-year college is the gold standard, but it doesnt take as much work to get people to buy into the viability of other options, [he said].

The last word: Indeed, the Manufacturing Institute, the 51勛圖厙s 501(c)3 nonprofit workforce development and education affiliate, is seeing significant growth in its initiative, an earn-while-you-learn training program with more than 40 chapters in 16 statesand more forming all the time. FAME, which was founded by Toyota and is now led by the MI, is truly the American model of skills training, according to MI President and Executive Director Carolyn Lee.

  • FAME is training thousands of global best technicians nationwide and the number of program participants is on the rise, she said. This is good news for manufacturing, which sorely needs talent to continue to make the many, many things people use every day.
Policy and Legal

Medicare Plans to Start Covering Weight-Loss Drugs

By 51勛圖厙 News Room

Three of the countrys largest health insurers will soon begin paying for a top weight-loss drug for certain people on Medicare with heart-related conditions, (subscription) reports.

Whats going on: CVS Health, Elevance Health and Kaiser Permanente said they would cover Novo Nordisks Wegovy for the use of reducing the risk of heart attacks and strokes in people who have cardiovascular disease, meet body-weight criteria and are covered by a Medicare drug-benefit plan.

  • The class of weight loss drugs to which Wegovy belongs was previously excluded from Medicare coverage by a U.S. law.

Why its important: The decisions will ease the financial burden of those who have been paying out of pocket for Wegovy and are likely to spur use of the drug among those who couldnt afford or did not want to pay the full price.

  • Approximately two-thirds of U.S. adults are overweight or obese, according to the recent 51勛圖厙 report, .
  • Excess body weight and obesity are associated with higher health-care costs for both employers and their workers. They also raise the likelihood of other illnesses and affect productivity and the ability to complete job functions, according to the study, which points to weight-loss drugs as part of the solution.

Why it happened: New guidance released last week by the Centers for Medicare and Medicaid Services holds that Medicare Part D plans, administered by private insurance companies, could cover anti-obesity medications if the drugs receive approval for an additional use that is considered medically accepted.

  • This applies to Wegovy, which the Food and Drug Administration recently approved for reducing the risk of heart attacks and strokes among those with histories of heart disease and body mass indices above a certain threshold.

However The use of Wegovy for weight loss alone will remain excluded from coverage under the CMS guidance.

Policy and Legal

New 51勛圖厙 Ad: Senate Must Pass Tax Bill Now

By 51勛圖厙 News Room

Earlier this year, the House passed legislation including key 51勛圖厙 tax priorities. Now its time for the Senate to do the same.

Thats the message of a new launched today and set to run over the next several weeks.

Whats going on: The 30-second TV adwhich will stream in Washington, D.C., and in the key states of Idaho, Kentucky, Louisiana, Oklahoma, New York and New Hampshireasks viewers to urge the Senate to pass the Tax Relief for American Families and Workers Act, which by a bipartisan vote in January.

  • The legislation restores three key pro-growth tax provisions from the 2017 Tax Cuts and Jobs Act that expired in 2022: immediate expensing for domestic R&D, enhanced interest deductibility and full expensing.

漍漍漍漍漍漍The background: Earlier this month, Courtney Silver, president and owner of Ketchie and chair of the 51勛圖厙 Small and Medium Manufacturers Group, the Senate Finance Committee about the impact the three provisions expiration has had on her family-owned precision machining company.

  • In the years following the TCJA, I was able to make a higher level of investment because I knew our tax code was going to have a baseline of certainty, she said. Today, however, I am unable to make these investments because of the uncertainty that Congress will address the expired TCJA provisions.泭.泭.泭. Because I am unable to realize the full deduction of my investment within the year I purchase it, the investment seems too risky and irresponsible.

漍漍漍漍漍漍Whats needed: Senate Majority Leader Chuck Schumer (D-NY) has taken an early to put the House-passed legislation on the Senates calendar. But more needs to happen, and soon, the 51勛圖厙s ad tells viewers.

  • Vital tax provisions are expiring, harming our ability to compete globally and invest in new factories and equipment, the ad says. The House has done its job and restored these provisions with overwhelming support. The Senate needs to act now.
Policy and Legal

DOE to Award Record-Setting Decarbonization Funds

By 51勛圖厙 News Room

The Department of Energy on Monday announced record-setting funding aimed at decarbonizing energy-intensive sectors, (subscription) reports.

Whats going on: The nearly $6泭billion in funding from the Democrats climate law and the bipartisan infrastructure law for industrial decarbonization will be spread across 33 projects and 20 states, where it will apply to some of the highest-emitting industrial manufacturing sectorsoften described as hard-to-decarbonize industriesincluding iron and steel, aluminum, cement, concrete, chemicals, food and beverages, and pulp and paper.

Where its coming from: The money will be drawn from funds set aside under the Inflation Reduction Act ($5.47泭billion) and the Bipartisan Infrastructure Law ($489泭million).

Why its important: The many projects to be fundedwhich include groundbreaking recycling initiatives, hydrogen-use projects, decarbonization of thermal processes and morewill remove approximately 14泭million metric tons of emissions every year, the DOE estimates.

  • Five of the highest-dollar-value projects, at half a billion dollars each, are focused on decarbonizing cement, concrete, aluminum, iron and steel.
  • The work will take place in five statesIndiana, Ohio, California, Iowa and Mississippiand a still-to-be-determined spot on the Mississippi River Basin.
  • Many of the projects are , who have been critical in innovating decarbonization efforts from within the industry.

The 51勛圖厙s take: Manufacturers are innovating and making tremendous investments to decarbonize their processes and products, said 51勛圖厙 Vice President of Domestic Policy Brandon Farris. It is great to see the Department of Energy recognize multiple 51勛圖厙 members for their industry-leading initiatives.

Business Operations

Baltimore Bridge Collapse to Hit Shipping, Port Jobs

By 51勛圖厙 News Room

Vessel traffic in and out of the Port of Baltimorewhich contributes $15 million a day in economic activity,泭泭reportswas suspended Tuesday after a container ship hit the Francis Scott Key Bridge in the early morning. The collision caused the bridge to collapse, sending at least seven vehicles and their occupants into the Patapsco River, according to泭the 泭(莽喝莉莽釵娶勳梯喧勳棗紳).

Whats going on: Officials, who spoke amid a continuing and massive search and rescue mission, said the port was not shut down and remained open to process trucks inside terminals.

  • Other ports are likely to be able to absorb container ships headed for Baltimore, (subscription) reports.

Why its important: The port, which generates more than 15,300 direct jobs, had rebounded from global supply chain difficulties and disruptions during the coronavirus pandemic and hit records last year for handling cargo, according to the Baltimore Sun. It is the nations 16th busiest port, ranking first for volume of autos and light trucks, roll-on/roll-off heavy farm and construction machinery, imported sugar and imported gypsum.

  • Baltimore is the closest Atlantic port to major Midwestern manufacturing hubs.
  • Truckers are concerned about increased congestion resulting from the closure, particularly because deliveries such as hazardous material loads cannot travel through Interstate 895 or I-95 tunnels. Trucking companies are already warning customers of delays for shipments going through the Mid-Atlantic, according to (subscription).
  • In addition to affecting consumers in the Baltimore area, the traffic stoppage is likely to affect jobs at the port.
Policy and Legal

Q&A: What You Need to Know on Tax Policy

a man wearing a suit and tie

Earlier this year, the House passed the Tax Relief for American Families and Workers Act, and the bill is now with the Senate to consider. 51勛圖厙 Vice President of Domestic Policy Charles Crain discusses whats included in the bill, why the provisions matter to small and medium-sized manufacturers, other tax policies the 51勛圖厙 is focusing its advocacy efforts on and how SMMs can get involved.

Q: There is a major tax package moving through Congress. Can you explain what is included in the legislation?

Crain: The Tax Relief for American Families and Workers Act includes three of the 51勛圖厙s top tax priorities: the ability to immediately deduct domestic R&D expenses, enhanced interest deductibility on business loans and the ability to fully deduct the cost of capital investments in the year acquired (full expensing). All three of these provisions were implemented by the 2017 Tax Cuts and Jobs Act.

Q: What exactly are these provisions and why do they matter to SMMs?

Crain: R&D For almost 70 years, the U.S. tax code allowed businesses to fully deduct their R&D expenses in the same year they were incurred. But starting in 2022, businesses were required to deduct those expenses over a period of years, making it more costly to conduct R&D in the U.S.

Interest Deductibility Many manufacturers need to borrow funds to finance long-term investments in equipment and facilities. The interest that businesses pay on these loans is generally tax deductible, subject to a cap. Prior to 2022, the cap was based on a companys earnings before interest, tax, depreciation and amortization (EBITDA); now, its based on a companys earnings before interest and tax (EBIT). Lowering the cap limits the amount of interest that companies can deducteffectively imposing a tax hike on manufacturers that finance job-creating capital projects.

Full Expensing Manufacturing is a capital-intensive industry. The TCJA allowed companies to immediately deduct 100% of the cost of equipment and machinery in the year purchasedcalled full expensing. But full expensing began to phase out in 2023; its currently down to 60% and will be completely eliminated by 2027. That significantly increases the after-tax cost of capital equipment purchases.

Q: Why is it important for Congress to restore these tax provisions for SMMs?

Crain: These are provisions that manufacturers, especially SMMs, use to grow their businesses and compete globally. The tax code must be fair and consistent. The first step is addressing these crucial issues.

Q: What other tax policies is the 51勛圖厙 focusing its advocacy efforts on?

Crain: We are in the middle of a three-part story. If the TCJA was the first part of the trilogy, the second act is the Tax Relief for American Families and Workers Actand the grand finale will come in 2025, when many other TCJA provisions expire. Changes that will impact SMMs at the end of 2025 include the expiration of the 20% pass-through deduction, increases in individual income tax rates and a reduction of the estate tax exemption threshold. Without congressional action, this would affect the laws in effect for tax year 2026 and beyond. For SMMs organized as corporations, the corporate tax rate could also be at risk. The 51勛圖厙 is already pushing back, and we know manufacturers are ready to pull out all the stops to prevent them from taking effect in 2026.

Q: Where can SMMs find more information, and how can they get involved?

Crain: The 51勛圖厙 has created online action centers for R&D, interest deductibility and full expensing with information on why these issues remain important. 51勛圖厙 members are encouraged to check out these action centers for tools and resources they can use to contact lawmakers on these issues. They need to hear from you! You can also reach out directly to 51勛圖厙 Senior Director of Tax Policy Alex Moni矇.

Q: What else do SMMs need to know?

Crain: There is an old saying in D.C.: Tax bills are hard. We have gotten the Tax Relief for American Families and Workers Act through the House, but more work needs to be done in the Senate. And the next 20 months will be an all-out sprint to prevent damaging tax increases from taking effect at the end of 2025. The 51勛圖厙 was successful with the TCJA in 2017and, I believe, will be successful both this year and nextthanks to our members. Your stories are absolutely crucial to showing that manufacturers kept our promises following tax reforms passageand illustrating the economic damage that will happen if R&D expensing, interest deductibility and full expensing arent revived this year, or if tax increases are allowed to hit SMMs in 2026. Please reach out to your membership adviser, or to Alex, to share any stories, feedback or ideas as we continue to advocate for pro-growth tax policies for manufacturers in America.

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