Monthly Archives: March 2023

Lean Workshop Group event programme to drive operational excellence

North East engineering and manufacturing companies will be given support in driving operational excellence through Lean Tools & Techniques and Industry 4.0, with a series of events next month.

The Lean Workshop Group in collaboration with the Sustainable Advanced Manufacturing (SAM) Project are running two events at the Industry Centre in Sunderland on Tuesday 18 and Wednesday 19 April 2023.

The Lean Workshop Group is a consortium of eight of the most innovative suppliers to the manufacturing sector: Bosch Rexroth, Spitfire, SICK UK, Orgatex, Bosch Power Tools, Visual Management Technology, WERMA Signaltechnik and K Hartwall.Harnessing a wealth of expertise in their specialist fields, the partners will provide companies with insightful tips and practical takeaways that they can implement in their business to bolster operational resilience, enhance inter-department connectivity, improve efficiencies and strengthen its competitive position.

There will be an opportunity to participate in practical and interactive session, using advanced equipment from the partner companies to put into practice Lean Management and Industry 4.0 techniques. Key topics will be covered including Visual Management, 5S (Workplace Organisation), Standard Operation Development, Work Content and Workplace Design, Logistics Operations, KANBAN Systems, ANDON, Intelligent Sensor Technology, Fundamental Skills Training, Cordless Power Tools, Autonomous Mobile Robots and Industry 4.0 Applications.

The events will be hosted by SAM, a £10.9m project to support the implementation of product and process development and the introduction of technology within the SME manufacturing base in the North East Local Enterprise (NE LEP) area.

Kevin Jones, partner at the Lean Workshop Group, said: “These workshops will be an excellent opportunity to review your processes, and listen to experts as they help move your company into the digital manufacturing age.

“Integrating lean management and Industry 4.0 into business processes to address pain points provides manufacturers with a host of benefits such as real time data to accelerate management, data driven quality control and training in virtual reality to improve working conditions.”

Roger O’Brien, Project and Technical Lead at SAM, added “We are pleased to be working with the Lean Workshop Group and promote areas of best practices to manufacturers in the region. The manufacturing sector is key to the North East and embracing the latest technologies that will be demonstrated in this event, and via our SAM facilities, will support companies to be more productive, competitive and meet some of the economic production challenges facing them in these challenging times. We encourage manufacturers to join us for this event for an insightful and thought provoking day.

The events will be held between 10am and 3pm on Tuesday 18 or Wednesday 19 April 2023 at the Industry Centre, Sunderland. For more information and to book click here

A Manufacturers Guide to… Industry 4.0

Since starting my engineering career +20 years ago, manufacturing has evolved at pace, with new technologies, processes and practices that have been introduced year on year.

This is a relatively new era of manufacturing centred around automation, real-time data, and interconnected technology that has the ability to boost efficiencies, productivity, predictable maintenance and profitability for businesses.

Industry 4.0 represents a significant shift that is occurring in manufacturing, this is not a buzzword, but clear changes that are happening in organisations that are seeing real value in smart digital technologies and the use of virtual machine twins using artificial intelligence (AI).

From robotics and autonomous equipment to 3D printing and the Internet of Things (IoT) with connected devices, businesses that are adopting these new technologies and are already realising the potential of Industry 4.0.

For example, look at engineering simulators. Now, you can use multi-physics simulators to determine if your product will achieve its design goals without the cost of many prototyping concepts, “almost a design-simulate and build once approach”.

This can also be seen in big manufacturing data analysis, with a combination of AI to enable prediction and answer ‘what ifs’, which is especially important if there has been an early adaption to an extensive digital twin, which can then be used to produce early virtual manufacturing data.

Accelerometers, a sensing device that produces an electrical signal in response to a mechanical vibration, have also advanced, they used to be so difficult to setup, but with the evolution of microelectronics and IO-Linked technology, there are now virtually plug and play.

This type of technology has already been embraced by industries such as aeronautics, space, defence, and automotive manufacturing, but there are still challenges for SMEs looking to drive an implementation plan.

There is a greater need for ease of use for new manufacturing technology, which will in turn reduce costs and enable a quicker return on investment, which is especially important for SMEs.

Since working at the SAM project, I have supported a number of SMEs looking to explore the possibilities and benefits of implementing smart technologies.

For example, we’ve had several successful demonstrations using microcontrollers, designed to be configured by non-software engineers. The User Interface is configured so you simply select what action you want when a button is pressed. I see this as a great leap forward in the market, having internet enabled devices have had a lot of consideration in the ease of use, as a consequence you’re not likely to require additional personnel.

The SAM Project has also supported SMEs in the region to understand what is achievable with new technology through knowledge transfer, and we have used experimental data to correlate Finite Element Analysis for many projects to validate if designs are fit for purpose.

With the introduction of smarter manufacturing technologies being pioneered by the larger OEMs, these technologies are filtering down to smaller businesses as their production data may be required by their suppliers “a product supply web”.

Imagine, a secure global interconnected bi-directional manufacturing network which can see not only their supply chain but other suppliers too. This will require both people and tools to achieve this, so the future is bright for smart advanced digital manufacturing.

A manufacturers guide to… Additive Manufacturing

Additive Manufacturing (AM) – or 3D printing as it is often referred to – is a method of creating a three-dimensional object, layer-by-layer, using a computer created design.

AM moves very quickly. Over the past few years, we have seen metal 3D printing go from something that is highly specialised and very high cost, to something that is achievable on desktop machines.

Material R&D has played a huge roll in the uptake of additive as materials are easier to work with and have far better properties. The software has also developed with some pace and we are now seeing topology optimisation and bespoke objects that could have only been produced via 3D printing.

My interest in 3D design began with design and modelling for 3D animation. The switch to making functional parts, especially those which are 3D printed, came about as I needed some parts for a research degree that I was working on at the time at the University of Sunderland.

I joined the team at the university’s FabLab when that opened and supported a number of companies who were looking for 3D prototype parts and when the SAM Project began, it offered a fantastic opportunity to work with more advanced technologies.

Although I had worked with 3D printing prior to the SAM Project, it has been during my time here that I have really focussed on design for additive and how to get the most out of all the different technologies that are available.

I have worked on numerous AM projects at SAM, they include those that I have led on that focus on all aspects of additive, as well as supporting the work of my colleagues who frequently require parts and prototypes produced for their projects.

Additive is hugely impactful as it is one of the easiest ways to produce a part, simple or complex. This is allowing us to rapidly prototype and evolve designs.

In the North East, we are still seeing additive being used mainly for prototyping, but I think there is huge potential for it to have an impactful roll within traditional precision engineering firms for work-holding and jig production that could significantly increase productivity.

The two areas that we are seeing the most development in are materials and speed. Machines are now working with a broader range of materials than ever before, sometimes combining multiple materials in the same part. Machines are becoming faster and faster and in shorter runs can be more competitive than injection moulding. They also enable the mass customisation of parts in each build and allow complex assemblies to be printed as one piece.

For those interested in learning more about the uses and benefits of 3D printing, it has never been easier thanks to the support available through the SAM Project. To find out more about the support and how your business could benefit, contact the team today.

A manufacturers guide to… CNC machining

Computer numerical control (CNC) machining is a form of manufacturing which uses software to control machine tools such as lathes, mills and 3D printers.

When I started out in the industry over 30 years ago, it was a relatively new, untested technology which was primarily used by the injection mould tool industry.

At the time, it was still in its early stages, meaning the majority of projects conducted using CNC machining simply involved old, punched paper feed or direct control input.

As the years have progressed, CNC and automated manufacturing have become somewhat commonplace across the industry and almost a requirement of modern-day manufacturing, reducing costs and significantly improving efficiency and quality.

My career – as a specialist in CNC – has echoed this. Since starting out in 1990, I’ve gone on to work with all kinds of workshop equipment, from manual mills to high end 5 axis mill/turns, 3D printers, laser cutters and CAD/CAM software.

This has seen me work on projects utilising CNC to produce everything from injection mould tools to tyre moulds, precision components, motorsport and F1 parts, aerospace components, film and TV props and even kitchen cooker hoods, you name it.

And it’s not just the large companies who are benefiting from embracing CNC. Here at the SAM Project, we’ve invested thousands into state-of-the-art CNC-enabled machines and software to help the region’s SME manufacturers test out the technology and understand its many benefits.

This has seen us work on numerous projects that have involved using my knowledge of manufacturing and CNC machining, with the biggest impacts being reduced timescales, improved accuracy, and repeatability where batch work is involved.

One of the key benefits is the ability for the equipment to complete a task without supervision. This allows the operator to complete other tasks during the manufacturing cycle which – at a time when manufacturers are facing a critical skills shortage – is a huge boon for those that have embraced CNC machining.

CNC machining is also able to produce parts with incredible precision, as the machine is controlled by a computer program that follows a set of pinpoint instructions. This means the finished parts will be more accurate and consistent than those produced using traditional machining methods.

As well as increased output and productivity, CNC also provides greater design flexibility by allowing manufacturers to produce a wide variety of complex parts and designs, as the computer program can be easily modified to produce different variations of parts. This allows manufacturers to be more flexible and responsive to changing customer needs and market requirements as demand ebbs and flows.

Contrary to popular belief, automated technologies such as CNC haven’t de-skilled the industry, either. Whereas much was made of the rise of the robots ‘replacing humans’, it has simply changed the skills required of workers, moving good machinists from hovering over machines to retraining them to program the machines, utilising their knowledge in a whole new way while adding extra skills to businesses.

As for the future of CNC machining, I feel that the relationship between CNC and 3D printing will continue to evolve, with machines capable of performing both techniques simultaneously and becoming more commonplace across the industry.

Over the coming years it is also likely that it will continue to evolve and become even more accessible to SMEs. New developments in technology such as machine learning and automation are likely to further increase the accuracy and efficiency of CNC machining, making it a must-have technology for any manufacturer.

Thankfully, for those interested in learning more about the manufacturing benefits of CNC machining, it has never been easier to trial the technology thanks to the market-leading equipment and support available through the SAM Project. To find out more about the support and how your business could benefit, contact the team today.

Martin Officer, Advanced Manufacturing Technician

A manufacturer’s guide to… AR & VR

I’ve worked across different areas of design for 25 years, spanning graphics, web, user interface and experiential design through, more recently to XR:- Extended reality which essentially encompasses VR – Virtual Reality and AR – Augmented Reality.

Running the “Game and App Design” degree at University of Sunderland cemented my interest in the potential of VR, I could only see it growing, improving and becoming central to digital communication.

Applying these same skills across industrial and manufacturing contexts reinforced my view as to the value it offers. For example, accelerating training, enhancing design review, facilitating remote collaboration. AR and 3D scanning, share the same upward trajectory, adoption is growing and we are seeing increasingly innovative and effective adoption of these. Part of my role is in helping SME’s understand and identify how these technologies can be applied to improve their process.

Advances in the XR sector are rapid, in respect of both software and hardware solutions, alongside a lower cost point, this is broadening sector adoption. VR and AR are mature technologies. At its inception 25+ years ago, VR was an industrial application technology – bespoke computers were needed to create experiences and run it. Advances now mean there is more processing power to drive both VR and AR creation and the devices to run them. AR can be delivered on smartphones and tablets, whilst standalone VR headsets cost as little as £400. Affordability has democratised delivery.

There’s a better understanding of VR/ AR and how they can support core industrial and manufacturing processes. VR is increasingly used for accelerating training, creating digital twins, collaborative design review and production planning at 1:1 scale. AR aids field service support and predictive maintenance, drawing on IIoT (Industrial Internet of Things) data for maintenance monitoring, asset tracking, and mapping 3D models to the physical world.

The evolution of computer processing has been key. GPU processing hugely improves rendering and frame rates, vastly enhancing the experience. VR experiences feel more realistic, AR tracking is more stable. Headset cameras map experiences to the physical space of the viewer. Increasing use of hand tracking eliminates the need for controllers, voice recognition leaves operatives free to work as they normally would, ‘gesture free’. Haptic technology, with its induced ‘forced feedback’, is also improving.

Crossover and inter-connectivity across technologies is also driving things forward; the ability to bring 3D scanning into both VR and AR at scale, to compare CAD against physical parts, or to conduct remote design reviews. All of these can prove invaluable and cost effective.

Using both data – pulling information into experiences in real-time, and AI for calculating and rendering events in real-time – are ever evolving and being applied to simulation for true digital twinning.

Sectors with the biggest development and investment budgets have been those quickest to embrace, notably Aeronautics and Automotive. They can deploy at scale and have the infrastructure to support and develop ‘services’ through R&D. The ROI – return on investment – is easier to identify and they can factor ongoing cost into their budgets.

It’s harder for SMEs who must prioritise investment in new technology. It’s not simply financial, there are many misconceptions, not least the perceived cost, that make firms pause. Many don’t understand how they’d use VR and AR. It’s part of my role to help companies understand this and identify ROI.

In my role, no two projects are the same. We helped a company visualise a digital prototype design for a standing desk at scale using VR and AR. Harnessed AR on modular building site platforms as a visualisation tool for construction planning. Captured large area scans of factories and took these into VR where they can be moved and edited. Used AR to break down complex assembly sequences to improve operative understanding.

Globally, investment in XR technology is strong, pushing the technology ever further, there are no signs of this changing.

The big tech companies, Apple, Meta, Windows, Samsung, Google etc. continue to invest heavily. As a result there’s a number of development/ delivery platforms: ArKit, ArCore, MRTK, OpenXR, ioX, major vendors are fighting for market share. Rather than standardisation, I envisage increasing niche specialisms and AI and/ or data will be pivotal to VR and AR applications within the industrial and manufacturing sectors.

Digital transformation is a hot topic, AI and data is at the heart of this; as VR and AR prove effective ways of visualising, retrieving and using these, adoption will be more widespread as part of the larger ‘toolkit’ rather than standalone technology.