Tag Archives: SAM Project

Roger Thomas SAM Project University of Sunderland

Meet our AR and VR Expert

Virtual and augmented reality (VR/AR) are mature technologies that are quickly moving from ‘proof of concept’ to being widely adopted across the industry.

However, while there’s been strong take up by large manufacturers, particularly those in aerospace and automotive, adoption by smaller UK companies has been less widespread.

It can often be difficult for small companies to identify where such technology can add value to their operations and identify a potential return on investment.

Through my role, I help the region’s SME manufacturers to understand how VR/AR and other digital technology can help overcome business challenges, improve onboarding, staff training and also corporate decision making.

For those unfamiliar with VR, it is an immersive experience delivered via headset and is increasingly being used to accelerate employee training; setting completion tasks against virtual scenarios i.e. by re-creating technically involved or hazardous scenarios in which an apprentice or similar can undergo training ‘risk free’. It is also increasingly being used for remote design review and collaboration, meaning users in different parts of the world can enter the same ‘virtual’ space, in real time, to discuss CAD design iteration, factory layout and a whole host of other actions.

AR essentially uses devices to ‘overlay’ digital content into the real world, this can be CAD, simulation/ animation, video, audio, and documentation (such as PDFs).  This type of ‘digital twinning’ (utilising Industrial Internet of Things (IIoT) devices) is giving rise to ever more effective application scenarios; such as maintenance monitoring, remote inspection, asset tracking, field servicing and predictive maintenance (using live sensor data), guided training/ instruction, and job completion tracking.

As the cost of both VR and AR technology continues to fall, they are beginning to bring clear value to company’s core operations by making them more sustainable and scalable. There are many systems to choose from and SAM can support in identifying the right solutions. A company can also visit our Digital Factory at the University of Sunderland and directly experience using the technology first-hand.

Facilities include different VR headsets, Microsoft HoloLens 1 & 2, large area scanning to produce point cloud and thermal analysis (i.e., of factory environments), tablet devices, 3D scanning for part analysis and commercially available software authoring environments. 

Alongside our specialist support, the facilities also provide a no-risk opportunity to explore the potential that a range of digital technologies might bring to your operation and establish a roadmap for timely and cost-effective adoption. Visit us today to find out how your business could benefit.

RIchard-Eynon-AMAP

Meet our Electronics and Industry 4.0 Expert

Richard Eynon, Industry4.0 and Electronics specialist at the SAM Project, helps SMEs understand and embrace the latest innovations.

Despite the many technological advances that have transformed the manufacturing industry over recent years, many SMEs are still reluctant to invest in the latest Industry4.0, digital and electronic innovations due to a common misconception that you need the budget of an OEM in order to purchase and run the latest software and machinery.

Having accumulated over 20 years’ experience working with transducers in a variety of industries, I have seen the impact cost effective and retrofittable cyber-physical devices can have on SMEs, especially when it comes to productivity. For example, using Internet of Things (IoT) connected devices such as condition monitoring equipment, which include Vibration, Temperature, Humidity, and Proximity Sensors.  These devices can help SMEs monitor performance of their machines and identify potential breakdowns and failures before they happen, resulting in less machine downtime and increased productivity.

Our Acoustic sensors can also be used to validate (audio) data from the connected devices, with an option of further in depth spectrum analysis and can also be intrinsically safer to locate where physical access may be a problem.

This wide industry experience over many years has essentially made me ask better and more relevant questions to help manage and determine a successful design solution, which generally can exceed internal or external customer (client) expectations.  Many design concepts require multi-skilled individuals or groups to solve them and being within the SAM Project – and having access to our colleagues with their broad industry experience and a wide network of industry contacts – can quickly determine the validity of an idea from proof of concept to manufacturability.

SMEs interested in learning how new technologies such as conditioning monitoring can benefit their business can also trial the technology themselves at our state-of-the-art factory areas at the University of Sunderland. Boasting over £1million worth of market-leading equipment, one of our most popular devices is a Portable Monitoring System.

The equipment is small and cost-effective but is a great introduction for SMEs wishing to learn how to implement digital data gathering into their business without breaking the bank and our test factory provides the perfect opportunity for companies to de-risk any future investments in new technology.

All of this equipment is completely free for manufacturers to try out. So, if you’re thinking of investing in any new machinery or software over the year ahead, why not de-risk your investment by paying us a visit?

Artech Lighting

Capital investment leaves manufacturer beaming

A County Durham business is hoping to establish itself as a leading light in the world of manufacturing, as it continues to invest in the region and increase its global footprint.

Artech Lighting, based on the outskirts of Durham city, has invested in a Ultimaker S5 Pro 3D printer as it looks to bring the production of many of its lighting components back to the region, creating a number of new jobs in the process.

Additive manufacturing, a term for industrial 3D printing, is the process where a three dimensional CAD model is turned into a physical object. For Artech, this will bring several benefits, the most significant will be to reduce costs and lead times for parts as well as making in-house prototyping more efficient, making the company more competitive on the global stage.

Since its launch in 2017, Artech Lighting has made a commitment to support UK manufacturing, producing 100% of its product range at its facility in Durham and securing contracts to supply some of the world’s most high-profile developments, from the Dubai World Trade Centre to The University of Edinburgh and cinemas across Saudi Arabia. 

Stuart Hylton, managing director, said: “As one of the very few lighting manufacturers left in the UK that produces 100% of its products within our borders, we are incredibly proud to stamp our products with the Made in Britain marque and to fly the flag for UK manufacturing.

“While many businesses were hit by supply issues during the pandemic, we saw our business grow three-fold, as developers across the globe began to seek out products that not only offered sustainable delivery and lead times, but were also environmentally sustainable, and we would never have been able to achieve this had it not been for the fantastic work of our team over the last few years.

“Looking forward, the investment into our new 3D printing system will allow us to bring the production of even more components in-house, creating more highly skilled jobs, further driving down our carbon footprint and massively improving productivity, and we’re excited to see what the future holds.”

The purchase of the 3D printer was supported by matched-grant funding from the ERDF-backed £10.9 million Sustainable Advanced Manufacturing (SAM) Project led by the University of Sunderland.

The project is a collaboration between the European Regional Development Fund (ERDF), the University of Sunderland and the Northern Powerhouse Initiative and Industry, supporting the implementation of product and process development and the introduction of technology within the SME manufacturing base in the North-East Local Enterprise Partnership (NE LEP) area.

“The support from SAM has really been fantastic,” Stuart added. “Not only did they provide the funding required to invest in the machinery, but their guys also guided our design team through the entire process of identifying the right kit and ensuring we saw the maximum possible return on our investment.

“Prior to engaging with the programme, we always knew that embracing additive manufacturing would be key to sustaining the future of our business over the coming years, however the support from Carl and the team at SAM has helped us to achieve what we thought we would in three years, in just three months. I can’t recommend them enough.”

Artech Lighting is also making significant investment of its own into a series of factory upgrades, purchasing a second paint plant, press brake, profile roller and punch tool, as well as making substantial upgrades to its IT network.

Stuart said: “The Artech brand continues to be a major industry disruptor. We are willing to compete with the more recognised brands and offer equal or better quality, output, delivery and efficiency, but with significantly less cost with the added peace of mind that you are buying a UK manufactured product. It is a strategy that is working, as recognition of the Artech brand continues to grow.”

Carl Gregg, product and process design specialist at the SAM Project, said: “It’s been a real pleasure working with Stuart and the design team at Artech on this project.

“The SAM Project was set up to help the region’s SME manufacturers innovate and grow by breaking down the barriers to embracing new technology and to see Artech not only increasing its global presence, but also creating highly skilled jobs in the region following this investment, shows just how much of an impact the programme can have on those that engage with it.”

Meet our CAD/ CAM specialist

Ian Barrett, CAD and Engineering Specialist, tells us more about his role and how the SAM Project can help SMEs embrace CAD and CAM technologies.

Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) technologies were developed in the ‘80s and are now widespread across the industry, helping improve practicality and productivity for businesses the world-over.

Throughout my career, all of my roles have involved some form of design, especially during the early days of CAD adoption, from developing consumer products to large scale heavy engineering projects. I also have a vast knowledge of prototype manufacture (both rapid prototyping and small batch production) and testing.

This has helped me establish an excellent working relationship with customers and colleagues who – as a result – trust my judgement when it comes to all things CAD and engineering.  A business’ needs must be managed, and I take responsibility to gather the relevant information, design or fit a solution to overcome any issues, put them in place and ensure the manufacturer is satisfied and that – more importantly – the problem has been solved, and not just with a ‘sticking plaster’, so to speak.

Due to my experience, knowledge and role, I am actively involved in a whole host of engineering projects, carrying out design layout, concept and prototype design, design for manufacture studies, drawing creation, FEA studies and providing additional information to customers who may require support that is over and above the usual role of a design engineer.

The SAM Project, our Prototype Factory, at The Industry Centre, and most importantly, our staff, allow the region’s manufacturers to experience and benefit from technology and knowledge that – in usual circumstances – would be difficult to access. Especially for small businesses. It’s also all under one roof and on their doorstep, at absolutely no cost to their business.

Recent success stories include using CAD to help an SME manufacturer develop a transparent, bullet-proof security barrier for the armed forces. Not only did we design the modular framework and supporting accessories, we also provided a scale prototype allowing the customer to have meaningful conversations with not just the MOD but also their finance and funding bodies.

Another saw us work with a family-owned beauty salon which – prior to tapping into our support – had absolutely no manufacturing or design experience. We helped them develop their idea for an easy-to-clean, portable, mobile hygiene screen and brought the idea to life by creating a fully functioning prototype. They are now looking at selling the product across the globe.

So, if you’re an SME manufacturer in the North East wondering how you could benefit from adopting CAD, need to provide CAD data and are not sure the best route to do it, or get the most out of your current CAD installations, why not pay us a visit at the University of Sunderland and see for yourself how our support could benefit your business?

Hundreds of firms have secured grant funding from SAM, could you be next?

Since 2018, the SAM Project has helped over 200 North East businesses become more productive and sustainable by supporting projects that enhance products, processes and technology.

Central to this success has been its incredibly popular Grant Funding scheme, providing matched-funding grants of up to £50,000* for manufacturing projects that support the growth of new products and processes.

This encompasses funding towards new to firm production technology; new product validation (tests/ consultancy); process improvement capital investment; structure to support research and development implementation; external consultancy on a time limited basis linked to a manufacturing/ production project and other product and process development costs.

During the first phase of the SAM Project, spanning 2018 – 2020, this saw the Project distribute over £1million in matched-funding grants, helping add £41.7 million in GVA to the North East businesses that engaged with the programme, creating 290 direct jobs and leading to a 30.1% rise in sales.

And the team at SAM are confident that, following its three year extension to 2023, it will have an even larger impact on the sector going forward, after it saw its grant pot double in size – by a further £1 million – and its technical team at the University of Sunderland continue to grow.

Speaking about the grant funding, Claire Darling-Cooper, compliance officer at the SAM Project, said: “The Grant Funding scheme proved incredibly popular with the region’s SME manufacturing base during phase one of the project, so we were delighted when we received confirmation that it had been extended for a further two years until 2023.

“Not only did it help create jobs, but it also helped safeguard many more and as we look to re-emerge from the pandemic, business support initiatives such as this will be key to ensuring the region’s manufacturers have all the tools they need to compete on the global stage and continue to innovate and grow.

The grants are restricted for small to medium sized (SME) business in the North East Local Enterprise (LEP) area – spanning Northumberland, County Durham and Tyne & Wear – and are also accompanied by 10-15 days’ worth of fully-funded technical support from the SAM Project’s team of eight manufacturing experts, who combined, boast over 250 years’ experience working across the industry in a number of senior roles.

Claire added: “We know how much of a leap of faith it can be when investing in new capital equipment, which is why we provide the technical expertise required to really understand the technology and all of its pros and cons, ensuring we help de-risk each and every investment we underpin.”

One such company to benefit from the SAM Project’s Capital Grant scheme is Vixen Surface Treatments Ltd, a market-leading manufacturer of industrial wet and dry blast cleaning cabinets.

After engaging with the SAM Project, the company was able to receive an in-depth demonstration of how 3D CAD visualisation software could help improve both its design and sales processes, as well as securing the funding required to invest in state-of-the-art software from Solidworks to implement the technology into its business model.

Aidan Mallon, managing director of Vixen Surface Treatments, said: “The first project we completed after the investment saw us test the Solidworks software on a live project that we won. It was a €500,000 export order from a German aerospace company and I genuinely believe we wouldn’t have won that contract without including it in our offer. It really adds credibility and professionalism to our proposals.

“As a manufacturer you must explore every avenue possible to grow your business, be it investing in new equipment or tapping into expertise and funding – and business support from organisations such as SAM is vital to helping SMEs move forward.

“We’d just extended our factory prior to approaching SAM and wanted to move into Solidworks. The grant helped us secure the funding needed to do that and accelerated our growth, helping us gain a competitive advantage by massively increasing the quality of service we’re able to offer clients.”

Another company to benefit from the grant scheme is Chester-le-Street architectural metalwork specialist, Steelcraft Ltd. Since engaging with the SAM Project and securing a five-figure funding grant, the company has expanded its product offering and launched a new brand, Forjj, allowing it to diversify and sell its products directly to consumers across the globe.

“The team at SAM were absolutely amazing,” Liam Armstrong, operations manager at Steelcraft said. “Prior to engaging with them, our factory hadn’t changed in 20 years and we were struggling to see how we could scale up our operations while keeping costs and disruption at an absolute minimum.

“Using simulation software, they were able to create an identical, computerised model of our workshop and, working closely with our production manager, identify which machines and processes could be altered and moved to make space for the new machinery and improved workflow.

“We’d never have even thought about using digital twin software to visualise and improve our shop floor and – as a family-business – we could never have accessed something like this without the support of SAM.”

The grants are accessible by all manufacturing SMEs, who can also still engage separately in a technical project with SAM (this can often support or identify the need for a grant application or helps to specify their precise needs and focus on the benefit and returns). The grant award is 25% matched funding available to those in Tyne & Wear and Northumberland and 35% for those in County Durham. The grants can also be used to support the purchase of second-hand equipment, as well as brand new machinery kit and software, and can even be used for specialist services or testing needs that may be holding a company back.

Claire added: “Vixen and Steelcraft are just two of scores of success stories we’ve recorded through the Project’s journey so far and are evident of the impact this support can have.

“Not only do the grants help break down the barriers to investing in new technology but they also help eliminate other financial inhibitors to driving strategic development of both product and process.

“The only drawback for us is that we only have £1 million to give away. While it may sound like a lot, the first phase of the SAM Project proved so popular that the grant pot was empty well in advance of the project’s end date, therefore we’d recommend any manufacturer reading this who thinks they may be eligible to get in touch with us and find out more.”

Interested in finding out more about the SAM Capital Grant scheme? Visit: https://samprojectuos.co.uk/grant-support-helps-sustain-growth-for-vixen/ or email: sam.project@sunderland.ac.uk

Manufacturers across the North East are being urged to tap into grant funding and fully-funded technical support to help their businesses innovate and grow.

North East manufacturers urged to tap into support before it’s too late

Manufacturers across the North East are being urged to tap into grant funding and fully-funded technical support to help their businesses innovate and grow.

The Sustainable Advanced Manufacturing Project (SAM) was launched in 2018 to help businesses become more productive and sustainable by supporting projects that enhance their products, processes and technology.

Since then, the programme – which was originally due to end in December 2020 – has proved a huge success, providing over £1 million in matched-funding, as well as practical and research support to over 200 SMEs across the region and is set to continue supporting the sector after securing a further £6 million, taking it to June 2023.

The pioneering initiative was originally part-funded by ERDF – with a £2.6m commitment – and the University of Sunderland and industry, which invested £2.5m, and is aimed solely at small and medium sized manufacturers (under 250 employees) based in the North East LEP area, with an annual turnover of less than €50m (£45m approx.)

The project offers a range of assistance – tapping into significant academic resources, a team of industrial specialists and five distinct factories with more than £1m worth of equipment – to offer both practical and research support, ensuring businesses can access a knowledge bank comprising some of the industry’s brightest brains and most advanced technology. This extension has also seen SAM’s Technical Research and Development team grow, to offer even greater specialist industry support to companies.

Roger O’Brien, Research and Technical Lead at the SAM Project, said: “The first phase of the SAM Project was a huge success and we were delighted when we heard that the project was to be extended. Over the last two years, we’ve provided funding and support to hundreds of businesses and have witnessed first-hand the impact this has had, from safeguarding and creating jobs to transforming entire production lines.

“Since the pandemic hit, the impact it has had on the nation’s manufacturing sector has been catastrophic. However, it has also provided opportunities such as re-shoring and bringing back in-house previously sub-contracted works, as well as business diversification. Now, more than ever, manufacturers need our support and this funding boost will go a long way to helping many of the region’s SMEs adapt and grow as we look to re-emerge from this crisis and keep Britain’s economy moving.”

In phase one, the SAM Project provided matched-funded grants of up to £50,000 to SMEs across the North East LEP area for capital, product validation, equipment and other financial inhibitors to drive the strategic development of both product and process. This has continued in phase two, with an additional £1 million being put into the grant pot, together with some tweaks to the intervention rates (now at 25% in Tyne and Wear and Northumberland and 35% in County Durham).

An independent report commissioned to explore the impact of phase one also revealed that the programme helped create 270 jobs and added over £47 million in gross value to the regional economy. It was also revealed that SAM’s impact on innovation and new product development meant that the average TRL (Technology Readiness Level) – the scale on how new products are measured as being close to market launch – was a staggering 3.9 steps, with some clients jumping from Stage 2 up to Stage 9 due to SAM support.

“Our fully-funded technical advice and support is what really makes the SAM Project stand out from your traditional business support schemes,” Roger adds. “While there are many other grant funds out there to help businesses grow, there are very few – if any – which offer the intensive, personalised technical support that we do.

“Combined, our nine experts boast over 250 years’ experience working for an array of businesses, from blue-chip manufacturers to start-ups, with each of them specialising in their own individual disciplines, from additive manufacturing to automation and robotics, AR/ VR, electronics and process improvement, to name just a few.”

Roger concluded: “If you’re an SME manufacturer, then the engineers, researchers, grants and access to capital are here to help you adapt to the inevitable process changes facing us post-pandemic and to help take your business to the next level.

“Programmes like this are pivotal to ensuring the North East continues to lead the way in product, process and technology innovation – and we can’t stress enough how important it is that manufacturers get on board.

“There is only a set amount of money and technical support available, therefore – following the huge success of phase one – early registration is highly recommended.”

For more information on the Sustainable Advanced Manufacturing (SAM) Project, visit: https://samprojectuos.co.uk/

Heliguy SAM Project support

Tech investment leaves Heliguy flying high

A North East drone specialist is scaling new heights after investing heavily in its own manufacturing facility.

heliguy™, based in North Shields, has established itself as a go-to drone supplier for clients across the globe since its launch in 2006.

The company started life as a retailer of remote-controlled helicopters but has since grown into a full-service drone specialist, providing drones, bespoke accessories, servicing, repairs, custom integrations, product development, drone pilot training and end-to-end workflow support.

Over the past two years, this diversification has seen the company secure contracts with 38 police forces across the country, as well as the London Fire Brigade, Port of Tyne and a host of personal and commercial clients.

One recent project, for a police force in the South East of England, saw the company’s design experts produce a bespoke drone mount, allowing officers to test mobile phone and radio signal strength in hard-to-reach areas such as farms and rural roads.

Another design and manufacture project, working with a commercial client – Aerial Ashes – resulted in the team developing a safe, sensitive way of scattering ashes at beautiful and memorable locations, such as out at sea or on mountain peaks.

This expansion of its services – and the establishing of a dedicated manufacturing hub at its Orion Business Park base – has not only led to the company onboarding more clients, but also more staff, with its headcount in North Shields now at 28.

Ross Embleton, custom integration specialist at heliguy™, said: “We identified a gap in the market – quite early on – when the drone market was just maturing and swiftly established ourselves as one of the UK’s leading independent providers of drones and accessories.

“Since then, we’ve continued to invest in the business year-on-year, ensuring we continue to service our clients to the highest possible standard and continuing to create job opportunities for local people.”

Central to bringing product development and manufacturing in-house and growing the business has been a suite of state-of-the-art 3D printers that has allowed heliguy™ to design and produce parts at its North Shields facility, helping to slash lead and prototype times while reducing costs.

Ross Embleton from Heliguy based in North Shields has purchased equipment with support from SAM project. Photo with Carl Gregg (SAM Project)

The company purchased the printers after receiving technical support and a grant from the £10.9 million Sustainable Advanced Manufacturing (SAM) Project, which is a collaboration between European Regional Development Fund (ERDF), University of Sunderland, the Northern Powerhouse Initiative and Industry, set up to support North East (LEP) SME manufacturers to explore and introduce new technology to improve their products or processes.

The funding supported the purchase of a market leading Markforged X7 3D printer, which allows the company to print parts in reinforced carbon fibre and Kevlar and will work alongside its selective laser sintering (SLS) machine and a Formlabs Fuse 1 3D printer.

The firm also purchased a Form 3L SLA 3D printer in November and aims to acquire a number of surface finishing machines over the coming months as it continues to invest in its design and manufacturing capabilities.

Ross added: “Bringing the production of our components in-house was key to us broadening our horizons and expanding into new markets and the support we received from SAM has been key to helping us do that.

“Carl [Gregg] was fantastic as he really bought into the concept. After working with him to identify which areas of our business could benefit from additive manufacturing and which 3D printers would be best suited to our needs, we went on to buy a state-of-the-art Markforged composite printer that has helped us significantly slash costs and lead times.

“It has massively reduced design times too. Now, if the managing director or a client has an idea, we can create a physical, working prototype within a week as there’s no waiting around for third party suppliers.

“Aviation parts also need to be strong and light, therefore being able to print parts in carbon fibre and kevlar on the Markforged printer is a huge benefit to us. It’s really helped us to step our business up a gear and we can’t thank Carl and the team enough for all of their support.”

Carl Gregg, product and process design specialist at the SAM Project, said: “As a team of engineers who thrive upon helping businesses overcome challenges to growth, it was fantastic to work with heliguy™ and to become so involved in helping them plan for the future as they continue to innovate and grow and create jobs here in the North East.

“The SAM Project was set up to help the region’s SME manufacturing base improve products and processes by adopting new technologies such as additive manufacturing and heliguy™ is a prime example of just how much of a positive impact the project can have.”

Robotics Specialist

Breaking down the barriers to robotics

Neil Taylor, Automation & Robotics Specialist, explains why embracing robotics is key to ensuring SME manufacturers remain competitive.

When I was first appointed Robotics Programmer at the then Tallent Engineering, back in the early 1980s, the technology was often seen as somewhat of a threat to jobs, and a far-fetched concept by many others.

Based out of Aycliffe Business Park, in County Durham, Tallent Engineering, now Gestamp, was one of the first non-OEMs (original equipment manufacturers) to embrace robotics, and as a result grew from being a multi-product manufacturer with just a single site, which had a handful of robots, into one of the world’s leading automotive Tier One suppliers, specialising in specifically in chassis and suspension products in just a matter of years.

Having started out as a welder, my role as robotics programmer initially saw the company invest in 10 robots, which at that time, none of the staff had even heard of and saw productivity increase significantly, helping us ramp up the output of parts we were producing for the Ford Sierra, improving quality and drastically reducing lead times.

Fast-forward 40 years and Gestamp now has over 1,200 robots operating at its Newton Aycliffe site alone, (the largest none OEM population of robots on one site in Europe), with tens of thousands more in operation across the globe – ranging from robotic welding, both MIG & Spot, machine tending, bushing, inspection and palletising. Robots have been key to that growth and success, along with challenging the norms of traditional production.

However, despite the rapid advancement of robotic technology over the last few decades and the heightened adoption of automated processes by the majority of automotive OEMs and Tier One suppliers, many manufacturing SMEs are still yet to harness and embrace the potential of robotics within their operations, often believing them to be out of reach price wise or technologically challenging.

For many, their reservations are predisposed to thinking that they would unable to afford the technology, that the costs will far outweigh the business benefits, or that the skills required are out of reach, however this couldn’t be further from the truth in the majority of cases, especially with the emergence of technology such as collaborative robots (cobots).

Here at the ERDF-funded Sustainable Advanced Manufacturing (SAM) Project, we have a team of technical experts working shoulder-to-shoulder with the region’s SME manufacturers to help break down the barriers to embracing new technology and improving processes.

One such company to benefit from the support is Almet.  The Washington-based specialist fabrication business is set to increase its factory size by 12,000 sq  ft over the coming months as it invests in robotic technology in a bid to enhance its processes. Working with the team at SAM, Almet was able to explore how the use of robotic welding technology could benefit its business, as well as tapping into the funding required to support the purchase of its new equipment. It was also able to weigh up the various alternative and benefits of deploying either cobots or traditional industrial robots based upon their specific applications, needs, volumes and repeat orders.

Another success story to arise from SAM’s fully-funded support is Pilgrim Spirit. Based in Alnwick, the premium brand gin producer was able to receive an in-person proof of concept demonstration of state-of-the-art cobot technology. This demonstrated that manual handling errors could be significantly reduced and even eliminated by using an automate process, whilst allowing them to increase productivity and utilise what would otherwise be downtime by extending operations to a 24 hour basis. This is subsequently to be deployed in their facilities following on from the engagement with the SAM Project. Initially they had paid a visit to our home at the University of Sunderland’s Industry Centre to find out more about 3D printing, but following on from this and seeing the potential after paying a visit to our six specialist factory areas, which have seen over £1m invested in new technology, they broadened their thinking and looked at how automation could benefit them.

Boasting everything from robotic welding cells to palletising robotics, collaborative robots, sensors and automation, latest virtual/augmented reality technology, sophisticated 3D printers, including metal printers, plus much more, the factories provide the region’s SMEs with an opportunity to test out advancements in their sector prior to making substantial financial investment and has been well received by the industry since its launch in 2018. 

Not only do these facilities allow companies to fully-understand how the technology works and how it is relevant but, similar to Almet, it also allows the companies to access matched-funding grants to support the purchase and installation of these technologies for their business.

Recent independent reports show that companies who engaged in the first phase of the SAM Project reported significant growth and improvements, including such things as improved layout, increased productivity, being more competitive through adoption of latest technology and increases in quality.

Companies such as Almet and Pilgrim Spirit have seen business skyrocket, creating new jobs and winning numerous new clients or opening up new markets as a result of technology adoption, and specially robotics and automation.

Yet, despite a recent report by the British Automation & Robotics Association (BARA) revealing that UK industrial robot sales were up 7.5% in 2020 on the previous year, there are still scores of manufacturing SMEs across the North East that are yet to have their eyes opened to the huge, somewhat untapped potential of robotic technology and the support on offer to help them steal a lead on the competition.

While it’s pleasing and reassuring to see sales of industrial robotics increase, we must continue encouraging more of the region’s manufacturers, particularly our SMEs, to explore all of the avenues of support available to them as we look to step out from the pandemic on the strongest possible footing and ensure UK manufacturing becomes more and continues to remain competitive on the global stage.

It is significant to note that the UK lags behind other major manufacturing economies in its use of robotics, so not only can SMEs increase local market share, but they can also explore wider markets and bigger potential that have previously been untapped.

Not only do robotics help significantly improve productivity, but they can also lead to reduced operating costs, improved quality and less material waste and in order to further build on this heightened demand for industrial automation, we must continue to champion projects such as SAM.

So, if you’re a small to medium sized manufacturer, or even a business looking to begin manufacturing, talk to SAM today to find out how the support could benefit your business.

It could be just the push you need to step your business up a gear, be that via automation or any of the other technologies or product and process design support on offer from within the SAM team…

Almet using robots

Rise of the robots aids Almet expansion

ROBOT-tech is boosting business at a North East metal fabricators.

Specialist fabricators, Almet, is expecting turnover to increase by 40%, as it prepares to invest in state-of-the-art robotic welding technology and increase its factory size.

The Washington-based business is laying the groundwork to increase its factory size by 12,000 sq ft as it invests in technology to enhance processes, following support from the Sustainable Advanced Manufacturing (SAM) Project.

The company, created in 1995, started out supplying large businesses in the region with general metalwork requirements and soon expanded into the automotive and yellow goods industries. From one-off bespoke prototypes to batch production items, Almet manufactures and supplies a diverse range of products to customers including Nissan, Komatsu and Caterpillar.  

As the business developed, Almet built an in-house paint plant as well as launching their sister company Temla Laser, which is ran by Paul’s daughter Hayley and son Paul, providing the latest in laser cutting technology keeping up with the demand for services with a quick turnaround.

Working with manufacturing experts from the SAM Project, Almet explored the use of robotic welding technology sooner than anticipated, as well as receiving funding that will support with paint plant machinery and the purchase and installation of a cure oven.

Paul Almond, director at Almet, said: “The SAM Project has helped us with several programmes, the latest one being robotic welding. The support is invaluable to us, as we didn’t know the ins and outs of robotic welding, or if it would suit our process. SAM was able to show us live demonstrations and explore what we could actually achieve with the machines.

“We may have invested in this technology in the future, but it would have taken us considerably longer – probably another couple of years – to get there without the support from SAM. Now we’re looking to invest in robotics within the next six months, so they have really sped up the process and allowed us to get there faster, which is important to stay competitive within this industry.”

Almet is also expanding into the adjoining unit, increasing its current 17,000 sq ft factory to 29,000 sq ft. This will allow the business to move and expand its paint plant – currently based across the road – keeping everything under one roof.

Paul said: “The expansion will see us move our paint plant into the new factory so that we can take in higher quality paintwork and attract additional business. SAM is also helping us in the form of grant assistance to purchase a new oven and spray booth.

“Now that we’re getting the facilities in place, as a target within two years, we’d like to increase the turnover for both Almet and Temla by 40% and this will without a doubt create new, highly skilled jobs.”

He added: “The SAM team couldn’t have been more helpful. The main thing is the support and the feasibility study. They look at products and business to help implement technology much faster. They’re on the money and really know their stuff.”

The Sustainable Advanced Manufacturing (SAM) Project is a £10.9m collaboration between the European Regional Development Fund (ERDF), the University of Sunderland and the Northern Powerhouse Initiative and Industry, supporting the implementation of product and process development and the introduction of technology within the SME manufacturing base in the North-East Local Enterprise Partnership (NE LEP) area.

Roger O’Brien, head of AMAP, said: “It’s a pleasure to work with Paul and the team at Almet to help them explore how new technology such as robotic welding can improve processes, as well provide access to grant assisted funding to support business growth.

“The SAM Project was set up to help the region’s SME manufacturers improve processes and unlock potential in terms of innovation and growth. Almet is a great example of this in action and we wish them all the best as they continue to grow.”