Tag Archives: simulation

3D-Digital-Twinning

Meet our Simulation and 3D Digital Twinning expert

Rita Potts is the Business Process Improvement and Simulation Specialist at the SAM Project, specialising in 3D digital twinning and simulation.

Simulation has historically been primarily used by larger organisations and for major installation programs in the planning and de-risking of major change.

However, here at SAM, we’re helping break down these barriers to entry for SMEs by allowing them to test and understand the benefits of the latest 3D simulation software by applying the knowledge and techniques often used by major corporates to their operations.

We have numerous examples of companies benefiting from this, such as through our plant layout projects. Similar to the way large organisations use the software, we can help SMEs plan and re-arrange the layout and organisation of their factory on a digital twin model that helps them better plan for the future.

For one of our customers, the digital factory included everything the real factory did. It was a digital replica of the staff, shifts, process flow and capacity constraints, modelling exactly what happens. Then, with the team, we made changes to create a layout that improved output by around 30% in the same square footage. Using the software, we were able to test all ideas in the digital safe space before actually physically moving any machinery, so planning the change was extremely time and cost effective and resulted in increased productivity as all overheads stayed the same and output increased dramatically.

We have also used digital twinning to look at plants that do not exist yet. We have helped a number of customers with what we call ‘concept plants’. These customers have been either growing rapidly and needed to understand their future space requirements  or looking to potentially secure investment. We have successfully helped customers, who have been able to demonstrate to their own staff, boards and to potential investors, what the factory looks like and how it will work, when the business is still in the early stages of planning, with one of our customers securing around £2m of investment and allowing their growth plans to be fulfilled.

It is often difficult for owners and managers to disseminate ideas and plans which are not yet developed fully and the 3D digital twin software helps by turning such ideas and concepts into a visual representation that allows for shared understanding. For one SAM SME, this meant creating a virtual production so that staff could see in advance the changes that would be made to their current operations when moving from a static build environment to a flow line. It also aided the training of staff in how that change – which was a major cultural shift – would look and work, creating improved communication and smoother transition to new ways for working.

This powerful visualisation also works for the business’ customers too! Our help with a production line installation company to demonstrate their line and products to their customer, as part of a tendering process, won them two £1m contracts from a major customer. For another company, we benchmarked their product against other products on the market, clearly demonstrating the difference in environmental impact and benefits, enabling them to take an accurate digital working model to presentations.

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 our support could benefit your business.

SAM Innovation and Growth

SAM Features in The Journal

The SAM Project featured in The Journal, published in Newcastle in a special feature in March 2022.

The article covers all of the areas of expertise offered by the the project with an introduction to the Technical Team, alongside case-studies featuring companies who have received support.  There is also information about the grant funding the project offers.

The full supplement can be downloaded here.

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.