Tag Archives: University of Sunderland

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

New machinery helps worktop manufacturer apply the perfect finish

A North East worktop manufacturer has revealed how digital simulation software has helped the 25 year old business visualise a brighter future.

Nostalgia Work Surfaces (NWS), based in Washington, has cut costs and lead times and ramped up productivity after receiving support from a team of manufacturing experts.

After receiving technical support and funding from the £10.9 million Sustainable Advanced Manufacturing (SAM) Project, NWS was able to use state-of-the-art FlexSim software to help validate that they had the space required to install the new equipment required to achieve its future plans.

The firm had long considered investing in a new CNC saw to help improve its product quality and reduce lead-times, however the investment was substantial to elevate the cutting capability from traditional into the digital interface of next generation CNC machinery.

The support from SAM – which included an expert workshop on manufacturing management techniques and one-to-one support from a simulation specialist – meant NWS could use state of the art 3D simulation software to identify where the equipment would fit within its setup and avoid any installation pitfalls.

A grant also supported the purchase of a new CNC saw, which has significantly cut costs for the company and reduced its carbon footprint since its installation in July 2022, as well as being faster, more versatile plus reducing off-cuts and waste.

Alan Taylor, managing director at Nostalgia Work Surfaces, said: “We are really pleased with the impact the new CNC saw has had on the business.

“It has not only increased productivity, standards and reduced waste but it has also given the workforce a greater sense of pride, lifting their standards and attitudes to a new level.”

He added: “We couldn’t have done it without SAM. One of the key inhibitors to growth we’ve witnessed has been the inability to move our workshop around without impacting upon production and their support has been key to helping us overcome this challenge.

“Prior to speaking to the team, we would never have even thought of using simulation software as a means of re-designing our workspace and figuring out how to improve our processes. It would’ve just seemed like an alien concept.

“The grant also went a long-way to helping us purchase the machinery we needed. We really can’t recommend the support enough.”

Nostalgia Work Surfaces currently employs 13 people at its Swan Industrial Estate site, however Alan is confident that – despite the many challenges currently facing the nation’s manufacturers – the company’s recent investment will allow it to continue creating jobs as it looks to the future.

“Because of the ability of the machine, we are now able to take on more complex work, angles and curves, resulting in the manufacture of more complex products which would not have otherwise been possible,” he said.

“Looking forward, we hope this will not only allow us to introduce new product ranges and improve quality, but also create more jobs as we continue to innovate and grow.”

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, said: “It’s been fantastic working with Alan and the team on this project and seeing how the latest simulation technology can help businesses such as NWS break down their barriers to growth.

“Over the past few years, we’ve helped hundreds of companies just like Nostalgia explore how the latest industrial technologies can help them innovate and we’d recommend any SME in the region which manufacturers – or has plans to manufacture – to get in touch while the support is available.”

SAM in the frame for award

The team behind the SAM Project has been shortlisted for a coveted industry award.

The programme has been shortlisted in the Developing Future Talent category at the upcoming Make UK North East, Yorkshire and Humberside Regional Awards.

The SAM Project was launched in 2018 to help North East manufacturing SMEs 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 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, Project and Technical Lead at the SAM Project, said: “Being shortlisted for the Developing Future Talent award at this year’s Make UK awards is a huge honour.

“Over the last four years, we’ve provided funding and support to hundreds of manufacturing SMEs across the region and have witnessed first-hand the impact this has had, from safeguarding and creating jobs to transforming entire production lines, and this award is a reflection and endorsement of all of the team’s inspiring work during that period.”

Unlike traditional business support schemes, SAM prides itself on the technical support it provides to help the businesses it engages with de-risk their investment and ensure their operations are more economically sustainable.

Roger added: “Our fully-funded technical advice and support is what really makes the SAM Project stand out from your traditional business support schemes. 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.”

The Make UK North East, Yorkshire and Humberside Regional Dinner will be held at Pavillions of Harrogate on 3 November, 2022.

To find out more about the awards ceremony or to purchase a ticket, visit: https://www.eventbrite.co.uk/e/make-uk-north-east-yorkshire-and-humberside-regional-dinner-registration-384009271067

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?

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

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…