Monthly Archives: February 2023

Future focus at metal mesh marvels

The opportunity of working with SAM specialists was music to the ears of a firm of Hartlepool metal experts.

For almost 140 years, The Expanded Metal Company has driven product innovation in its sector, producing metal mesh products for construction materials, filters, grilles, walkways and visually striking architectural meshes.

The Expanded Metal Company was founded by the patentee of expanded metal, John French Goulding and has been operating on the same site since in 1889. Refusing to rest on its laurels, the company tapped into SAM expertise to help ensure the smooth introduction of a new product line.

The company was developing a modular cages range and accessed support from the team of University of Sunderland-based experts to help ensure smooth production processes and iron out some minor design challenges.

Managing Director, Phil Astley, said: “The main benefit of the SAM team is that it allows companies like ours to quickly access the exact expertise and guidance required when embarking on a new project.

“I was very impressed with their support and having first met with Roger O’Brien, we met his team at the University of Sunderland and before long we were working closely with them on the redesign of our security cage.”

The company has developed a “flat pack” security cage, a modular system that can be tailored to meet the exacting requirements of clients, which is shipped in a relatively small consignment and assembled on-site.

Kalem Ainsley, Technical Manager and Ryan Pinder, Operations Manager and Head of Continuous Improvement at The Expanded Metal Company worked with SAM’s automation and robotics expert, Neil Taylor, and CAD design expert, Ian Barrett, to hone design specifications and create clear, smooth production processes ahead of the product’s launch at the end of last year.

“By being able to transport the cage packed flat on a pallet we’re being more efficient and reducing our own carbon footprint, as we’re not transporting empty space,” added Phil.

“Alongside the development of our website, which allows customers to configure the cages to meet their own unique needs, this new solution is perfect for a wealth of sectors, as customers can select their own dimensions, colours, whether the cages need wheels…anything they require really.”

Employing 86 people, the Expanded Metal Company has also developed a range of innovative fencing systems and security solutions and serves sectors including construction, filtration, automotive, aerospace, architecture, manufacturing and engineering, agriculture, acoustics and security.

Ian Barrett, CAD and CAM specialist at the SAM Project, said: “The Expanded Metal Company may have been around for almost a century and a half, but it remains laser-focused on setting the pace in the future.

“It was a fantastic experience working with a business that boasts so much knowledge of its sector but remains open and enthusiastic about adopting new technology and processes.”

A manufacturers guide to… robotics

When I first got involved with robotics back in the early 80s, I naively didn’t even know what a robot was.

Starting out as a welder, the plant superintendent pulled me aside one day to ask if I’d be interested in becoming a robot programmer.

The company had purchased 10 industrial welding robots and my job was to learn all I could and ensure we were able to put them to use.

And put them to use we did. By the time I’d taken early retirement in 2018, we had successfully deployed over 1,400 individual robots across our plant, here in the North East.

The growth of the industry was phenomenal, and the automotive sector wasn’t the only one profiting. Industrial robots had arrived across the manufacturing spectrum and I was seeing this with my own eyes.

I took up a role with a major Japanese robotic supplier before setting up my own consultancy and helping install over 1,000 industrial robots across Europe, the US and Asia.

I was always in my element with a robot teach pendant in my hand and if this experience taught me anything, it was that the robotic revolution was well and truly underway…and it was no longer just for the blue chips and major corporates.

Returning to the North East, I began working with the SAM Project to help the region’s SMEs break down barriers to automation and robotics, just as our team did all those years ago.

In the two years since, the role has seen me work with everyone from sole traders to firms employing hundreds, helping them better understand and implement everything from robotic welding to automated canning lines and palletising robotics.

But it wasn’t until we held a recent jobs fair at The Industry Centre that I really had my eyes opened to the current issues facing the region’s employers and how robotics could help them innovate and grow.

The vast majority of manufacturers are facing huge challenges when sourcing skilled robotic engineers, which I predict will spark yet another robotic revolution.

Not like the previous one in the 80’s and 90’s, but a new generation of automation. It’ll be “The Rise of The Cobots”.

When I first took on the role at SAM, one thing that jumped out at me, not literally, was a Cobot or ‘Collaborative Robot’, sitting in the corner of the room.

Having been involved with industrial robots for the best part of 40 years, my initial thought was “its not a real robot, it’s something that will keep children happy, a toy”. How wrong was I?

It’s collaborative. It’s designed to work with you. It doesn’t stop for a break or to browse social media and it works in a “lights out environment”.

Not only that, it’s also easy to teach and can be deployed just about anywhere to do just about anything. For an industry facing a critical skills shortage, the Cobot could well be the sector’s saviour.

Automation promotes growth and, I believe, the Cobot could well overtake what we witnessed during the original robot revolution, so much so that the industrial robotic manufacturers are now even developing their own collaborative robots.

Cobots can and will fill the gaps in the current labour market. The UK manufacturing base is slowly waking up to the fact that Cobots can take away all of the dull, dangerous and dirty jobs, with increased output per hour, and just like 30 years ago, SMEs are fast realising the benefits.

So, if you’re an SME in the North East and have applications that you think could be automated, any mundane repetitive tasks, or simply a concept you would like to investigate automating, then why not contact the team today?

Our team of industry experts and academics have over 250 years’ industry experience, so whatever your challenge, you can guarantee they’ll have seen it before…

Neil Taylor, Automation & Robotics Expert at The SAM Project.

Manufacturing a brighter future for North East industry

The Sustainable Advanced Manufacturing (SAM) Project has been helping North East manufacturers to become more productive and sustainable by supporting projects that enhance their products, processes and technology for the past five years.

The programme – which was launched in May 2018 – has proven a huge success and benefit to the region, attracting national attention while forging an impressive reputation, as well as helping bring to market some notable new products and innovations.

To date, it has provided almost £2 million in grant funding to the region’s manufacturers, as well as providing practical and research support to over 300 SMEs, from sole traders all the way through to businesses employing hundreds of staff.

And with the programme set to run until June 2023, discussions are now underway as to how this significant support can remain accessible to the region following the end of European Regional Development (ERDF) funds.

The pioneering £10.9 million initiative is part-funded by ERDF, which invested £5.8 million, and the University of Sunderland and industry.

The project offers a range of assistance to eligible SMEs in the North East LEP area, allowing them to access and tap into the significant academic resources with the University’s Faculty of Technology, a specialist team of industrial experts and five distinct factories with more than £1 million worth of cutting edge equipment.

Through this, SAM is able to offer both practical and research support, ensuring businesses can access relevant knowledge comprising some of the region’s and industry’s best informed and experience practitioners, as well as access to the latest advanced manufacturing technology.

The SAM Project Technical Research and Development team has been drawn from industry with a diverse mix of backgrounds and skills to provide a unique and compelling offer of support to SMES in the region.

Roger O’Brien, project and technical lead at the SAM Project, said: “The SAM Project is, and has been a huge success, and we are delighted to be continuing to provide support to the region’s manufacturing sector, which is key to the regional economy, jobs, growth and position.

“Over the years, we’ve provided funding and support to hundreds of businesses and have witnessed firsthand the impact this has had, from safeguarding and creating jobs to transforming entire production lines. Last year alone we registered an additional 77 manufacturers onto the programme, as well as working with existing businesses, meaning 169 companies have now received support in the last 12 months alone.

“Since the pandemic and with the impact of Brexit, the nation’s manufacturing sector has faced more than its fair share of challenged. 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 the funding and support offered by SAM is key to ensuring many of the region’s SMEs are able to adapt and grow as we look to re-emerge from this crisis and keep Britain’s economy moving, and help prevent the UK from falling into a potential recession.”

The SAM Project has provided matched-funded grants of up to £50,000 to scores of SMEs, be it for capital, product validation, equipment and other financial inhibitors to drive the strategic development of both product and process.

The total grant pot was £2 million, which has supported approaching £6 million worth of private sector investment in new facilities and state of the art equipment, in nearly 80 businesses within the North East spread across all areas of the region and from a diverse mix of manufacturing sectors, from traditional engineering to those delivering cutting edge new products and processes.

An independent report commissioned to explore the impact of the SAM Project at the midpoint of the project also revealed that the programme helped create 270 jobs, over half of these directly as a result of SAM interventions and added over £47 million in gross value to the regional economy.

Two years on from that report and the success has magnified as the impact has continued to grow, with the project about to embark on a full impact assessment and evaluation for its full duration.

“Our fully-funded technical advice and support is what really makes the SAM Project stand out from your traditional business support schemes,” Roger added. “While there are many other grant funds out there to help businesses grow, there are very few – if any – and certainly none in the region, which offer the intensive, personalised, in-depth technical support that we do.

“We have delivered everything from concept designs, proof of concept studies, implementation support, factory layout, technology adoption and best practice, across the spectrum of advanced manufacturing. I am immensely proud of the support and benefit the project and team have made to the region, and hope this can continue to make a difference beyond June 2023.”

Roger concluded: “If you’re an SME manufacturer, then the engineers, researchers, grants and access to equipment are here to help you adapt to the inevitable process changes facing 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 before this phase of support ends.

“There is only a set amount of time and technical support available, as well as very limited grant funds remaining, therefore – following the huge success – registration as soon as possible is highly recommended.”

‘Made in Britain’ commitment leaves clothing manufacturer fighting fit

Enabling brands to bring the of their garments home to the UK has proven the perfect fit for a fast-growing clothing manufacturer.

Studio 54 Jesmond has unveiled plans to double its output and create three new jobs, following a period of significant growth.

Founded by fashion entrepreneur Amy Fettis, the Jesmond-based firm samples and manufactures athleisure clothing and accessories for brands across the UK and international clients.

Fusing activewear and loungewear, the athleisure market grew 84% during the first year of the pandemic, however mass supply chain disruption brought about by travel restrictions led to a dearth of produce for brands across the UK.

This led the forward-thinking entrepreneur, who had previously run her own athleisure clothing brand, to launch her own dedicated manufacturing business in 2020, bringing the production of goods onshore to the UK.

“Traditionally, the vast majority of athleisure products have been produced overseas and the pandemic really highlighted the dangers of this,” she said.

“As supply chains the world-over had their fragilities exposed by travel restrictions, companies who had safeguarded their supply by embracing sustainability and locally sourcing their products saw their efforts really bear fruit.

“It also led to more businesses embracing the idea of onshoring, which is where we have really benefited. Since restrictions were lifted, we’ve continued to see our business grow significantly and the rising demand for our products is showing no signs of slowing down.”

Based in a converted townhouse in the centre of Jesmond, Studio 54 offers bespoke sampling, development and small batch clothing production, which has made it a supplier of choice for independent and start-up fashion houses across the UK.

And having recently been backed by a venture capital fund and the £10.9 million Sustainable Advanced Manufacturing (SAM) Project at the University of Sunderland, the company has unveiled ambitious plans for the future.

“Entering into a joint venture with our VC partner, as well as the grant funding and support from SAM, has really allowed us to focus on growing the business,” she added.

“Over the coming months, the grant from SAM will see us invest in a suite of new industrial sewing machines and the VC support will see us create three new jobs as we continue to scale the business.

“We also plan to establish an off-site production facility next year too. Some clients are coming back with repeat orders and we don’t see this slowing down, so this will allow us to create bigger runs, which in turn will enable us to work with bigger brands.”

As well as helping Studio 54 Jesmond purchase new machinery, the support from SAM has also helped the company improve the quality of its products and identify other areas of the business that could be improved.

Amy said: “The SAM Project has helped us identify areas of our business that could be improved from the outset and improve our detailing. They have also introduced us to people in the industry and have kept us in mind when opportunities have arisen that could benefit us.

“They’re one of the only organisations that I know that are manufacturing focused and I think there’s a huge gap in the UK for organisations like this. So much offshoring has happened in the last 20 years and to have that dedicated support for manufacturers like us – who want to really champion UK manufacturing – is so valuable.”

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 SME manufacturers in the North-East Local Enterprise Partnership (NE LEP) area to improve their products or processes and introduce new technology.

Roger O’Brien, Project & Technical Lead at the SAM Project, “It’s been great working with Amy and the team at Studio 54 Jesmond to improve their means of production and make the business more sustainable.

“With a recession on the horizon and a seemingly ever-worsening climate crisis, it’s never been so important for businesses to ‘buy British’ and Studio 54 Jesmond is a fantastic example of how onshoring can help create jobs and bolster the economy.

“It’s been a pleasure working with them and we look forward to continue supporting them as they plan for the future.”