Industry 4.0 Magazine

THE MAGAZINE FOR THE FOURTH INDUSTRIAL REVOLUTION

issue no. 7 - DECEMBER 2018

IN THIS ISSUE North West Pilot Launched

Interview with Stephen Phipson CBE

Chief Executive of EEF, the manufacturer’s organisation

Product Design Trends to Keep an Eye on in 2019

Dave Grammer, Vice-President UK Nordics at PTC

How Can SMEs Leverage the Potential of 3D Printing

Britain’s Manufacturing Future. We’re here to enable it The Factory of the Future is coming to Britain soon and we’re here to help make it happen. British businesses are already taking their first steps to remain competitive in a world where customers demand customised products, faster delivery and shorter lead times. As leaders in drive and control solutions, we offer the digital solutions you need to maximise the opportunity of Industry 4.0.

The Factory of the Future is more than just a vision, so join us on our journey Now. Next. Beyond.

WE MOVE. YOU WIN. www.boschrexroth.co.uk/FOTF

Thank you for downloading The

Industry 4.0 magazine

Thank you for reading the 7th edition of The Industry 4.0 Magazine.

The first Made Smarter Pilot was launched last month in the North West of England. In this issue we look at what this means for UK Manufacturing.

Donna Edwards is driving the Industry 4.0 agenda in the North West – she talks to us about the direction of the initiative and the focus on enabling SME’s to become more efficient.

We are now 4 months away from our flagship event - The Industry 4.0 Summit. Our leading industry leader’s panellist, Stephen Phipson CBE, CEO and Chair, EEF answers questions on 4IR and his views on how it applies to the current scenario and the governments role in driving progress.

There is a lot of hype around 3D in manufacturing.

We look at how SME’S can leverage the potential of this technology.

The Digital Innovation challenge at The Industry 4.0 Summit is hotly contested by students from across the UK. We look at last year’s winner’s who created a 3D-printed robotic prosthetic hand and announce the challenge for 2019.

THE INDUSTRY 4.0 MAGAZINE IS PUBLISHED MONTHLY BY GB MEDIA AND EVENTS ORGANISERS OF THE INDUSTRY 4.0 SUMMIT PUBLISHER Gary Gilmour EDITOR

Pav Baghla

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Thank you for reading The Industry 4.0 magazine and we look forward to receiving feedback and contributions from our readers.

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We wish you a Happy Christmas and a prosperous New Year.

Pav Baghla, Editor The content of this magazine does not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for the loss arising from information in this publication. All rights reserved. No part of this publication may be producted or stored in a retrieval system without the written consent of the publishers.

Cover image Our front cover shows one of the giant bee sculptures that are found throughout Manchester. The motif of the worker bee has been widely used to represent the city of Manchester as a symbol of industry. The Manchester factories were sometimes referred to as beehives, because the workers within them were so busy and productive.

The news that the North West pilot will be based in Manchester is great news and will create new opportunities for growth and skills development in the local and regional manufacturing sector.

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Made Smarter North West Pilot Launched

12 21 29 4

Product Design Trends to keep an Eye on in 2019 Dave Grammer, Vice-President UK Nordics at PTC

How Can SMEs Leverage the Potential of 3D Printing

Show Reviews Future Robotics – Coventry, UK Electronica Munich – Germany

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Interview with Stephen Phipson CBE Chief Executive of EEF, the manufacturer’s organisation

17 27 31

Call for Entries to new £2,500 Student Digital Innovation Competition

PRODUCTS AND SOFTWARE For industry 4.0

INDUSTRY 4.0 SUMMIT & EXPO Exhibitor Focus

Made Smarter

North West Pilot Launched

Last month, the Industry 4.0 agenda in the UK took another important leap forward with the launch of the first Made Smarter Pilot here in the North West of England.

When the Made Smarter Review was published in October 2017, it gave a number of recommendations: to upskill a million industrial workers; inspire stronger leadership to drive change; and to create a more visible and effective ecosystem to accelerate innovation and the diffusion of industrial digital technologies.

The report, which was commissioned to assess how UK manufacturing could benefit from the increasing digitalisation and technological changes of Industry 4.0, found that SMEs are particularly reluctant to adopt new technologies.

Fears over cyber security and a lack of common standards were cited as barriers to adoption.

By creating a visible and effective ecosystem of partners, the new pilot here in the North West will directly address these fears while helping manufacturing leaders in SMEs to explore digitalisation and accelerate the adoption of Industry 4.0 technologies.

The pilot will also establish a student placement programme to help initiate conversations with SMEs to help identify where participating students might be able to implement a digital solution, and a leadership and management programme to support manufacturing leaders manage the change programmes necessary with the adoption of Industry 4.0 technologies.

Engaging and motivating new and existing teams is key to a successful transition to 4.0.

It is hoped the pilot will provide a route map towards digitalisation for manufacturing SMEs and serve as a blueprint for the rest of the UK. The Made Smarter Review has also helped to unlock £121 million for the sector to fund demonstrators or POCs, as announced in the budget as part of the government’s £1.1 billion Industrial Strategy Challenge Fund.

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To find out more about how the pilot will run, and how SMEs can engage with the initiative, Industry 4.0 magazine sat down with the Made Smarter pilot Director, Donna Edwards.

Leading the Industry 4.0 Agenda in the North West Donna Edwards is no stranger to engaging with North West businesses to drive change. She’s already been helping businesses pursue the digital agenda through her work at Business Link North West, The Manufacturing Institute and the Manchester-based Growth Company.

She will now be leading the Made Smarter pilot with the goal of increasing regional Gross Value Added (GVA) by £115 million. Siting the pilot in the North West was a key recommendation under the Made Smarter Review, and Edwards argues that the North West is uniquely suited as a location for the pilot.

With a varied geography and strong regional collaboration, as well as existing digitalisation and Industry 4.0 initiatives running in the region, Edwards is keen to stress the North West’s leading role in Industry 4.0.

“The North West has a tradition of working collaboratively to deliver business support programmes. We have a great history of innovation and a desire to work together. What’s more, the mix of urban and rural, varied geographies and industries, gives us an opportunity to test different ways of execution, because there isn’t a ‘one size fits all’,” Edwards says.

Under Made Smarter, the five local enterprise partnerships in the North West – Cheshire, Cumbria, Lancashire, Liverpool City Region and Greater Manchester – will come together to better support manufacturers to adopt digital technologies. These regional teams are already working with local manufacturers, so there is an “easier in” to start having conversations about Industry 4.0.

“We’re already working with SMEs to get them to Industry 2.0 and 3.0. Now we’re looking at getting them to Industry 4.0 and we need to understand the best ways to take them on that journey,” explains Edwards.

This means one of the objectives of the pilot is to establish the best ways to reach out to and speak with UK manufacturing SMEs; to identify what the triggers are that will drive engagement and action.

“We want to reach the people who don’t understand Industry 4.0 or who think Industry 4.0 is not for me.”

Donna Edwards, Made Smarter Pilot Director.

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MADE SMARTER PILOT

Issue no 7 - DECEMBER 2018

industry 4.0

Engaging with SMEs across the North West There can be a multitude of reasons why SMEs are reluctant to get involved with the Industry 4.0 agenda, whether it is not understanding the potential, or thinking Industry 4.0 is not for them, to those who have got their fingers burnt with a previous digitalisation project and are now suspicious about the value.

Edwards says, “Part of the challenge is the diversity of experiences we need to address.

We are working with some companies who have never done Industry 4.0; some who have had over-specified solutions, got their fingers burnt and never want to do it again; and those who have done a bit, but it’s not joined up or aligned with their business imperatives which means that the envisaged return on the investment is not being realised. There isn’t going to be one solution that’s right for every company. So, it’s important we don’t go in with preconceived ideas.”

With more than 14,500 manufacturing and engineering organisations in the North West, the pilot programme is tasked with engaging with 3,000 manufacturers in the region.

From that, it is envisioned 600 potential projects will emerge as active Industry 4.0 initiatives.

Edwards is keen to encourage SMEs who are interested in exploring what Industry 4.0 might have to offer them to reach out – either through the Made Smarter website or through their local business growth hubs where there will be a dedicated Made Smarter Adviser.

“Even if you’ve got no idea where to start, you can talk to an advisor and they can work with you to explore what the possibilities are for your company. All our specialist advisors will have been in industry and have done this for real; they’ve got the scars and know what is likely to work and what doesn’t work.”

Growing the Made Smarter Team Although just weeks old, the Made Smarter pilot already has two advisors on board; an AR/VR specialist and an additive materials specialist. A further eight advisors will join the team soon, with each advisor working with six different companies over the two-and-a-half years of the programme.

It’s hoped that this will allow each advisor to focus in depth on each manufacturing business and the projects with which they are involved, to ensure the business benefits are realised.

In addition, the pilot will build up a wider ecosystem of suppliers and consultants which will support the participating companies and advisors with detailed specialist knowledge where it is needed.

The relationships forged under the Made Smarter programme are very much seen as a long-term partnership, Edwards explains:

“Once we’ve identified some first steps, we will introduce them to potential suppliers.

The advisor will help them with those relationships and with the implementation. If we think the project has potential, we can suggest they apply for grant funding. The advisors are not going to start something and then drop them; we’re going to be with them for the lifetime of the pilot.”

To aid with these adoption projects, £20 million of funding has been put behind the Made Smarter pilot, with nearly half of that earmarked for grant funding.

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industry 4.0 Issue no 7 - DECEMBER 2018

MADE SMARTER PILOT

Making It Easy for SMEs Manufacturing companies interested in accessing the Made Smarter specialist advisors and funding for their own Industry 4.0 project should engage with the Made Smarter pilot team.

“SMEs will work with an advisor to identify a potential solution and who can deliver that solution. The advisor and the Made Smarter team will do some of that legwork,” explains Edwards, “we’re trying to make it as easy as possible for SMEs.” She expects funded projects to be a mix of proven concepts and truly innovative programmes. Ultimately, it will depend where participating manufacturers are on their Industry 4.0 journey.

But the success of the project isn’t only about initiating projects and accessing funding, explains Edwards: “It’s also about how we build confidence about changing the way manufacturers do what they do. They’ve been really successful businesses in terms of what they do and how they’ve grown those businesses based on how they do it now.

Embarking on a process to change how they do that is scary, especially in terms of control. We need to build that confidence and help them put in place processes that ensure they take their workforce with them on that journey.”

Crystal Doors: Proven Success Story One of the important tools for driving engagement will be the real-world results about what can be achieved through the adoption of Industry 4.0 technologies.

An early test of the pilot’s potential can be seen in the experience of Rochdale manufacturer Crystal Doors. Early improvements came through the installation of a new robotic arm spray-painting the manufactured frames. Now the business has implemented three separate automation projects.

Edwards says, “They’ve been able to increase turnover as a result of the introduction of automation. They’ve put a nightshift on and where they had three people working, they are now employing nine. Through automation the quality has improved, as have the production quantities; as a result, turnover has gone up. These are the positive stories we need to get heard.”

The Crystal Doors story suggests the pilot can succeed on its own terms. At the start of a project, the Made Smarter team will be working with businesses to identify opportunities to improve productivity and increase turnover and profitability.

These metrics will be revisited postimplementation to see how far they have moved, with the target GVA of £115 million for the pilot as a whole.

The Crystal Doors team are fantastically engaged evangelists, and this is exactly the community ethos Edwards wants to build through the pilot. She says, “This is what Made Smarter is about. We can support SMEs to innovate. We can put them in touch with a supplier. We can help them create, implement and then see what the difference is. It is about taking people on that journey but, ultimately, building a successful Industry 4.0 ecosystem. It is about SMEs talking to SMEs and building a community of engaged businesses to spread the message and support an increasingly broad range of digitally enabled businesses in the supply chain.”

Find out more: www.madesmarter.uk www.linkedin.com/company/madesmarteruk www.twitter.com/MadeSmarterUK 8

Interview with

Stephen Phipson CBE

Chief Executive of EEF, the manufacturer’s organisation

The EEF are the voice of UK manufacturing and engineering and a leading provider of business support. EEF works with a wide range of people, from industry leaders, managers and professionals, to young people, apprentices, policy-makers and the media. The organisation promotes and supports enterprise and innovation in the UK while making sure businesses remain compliant, future-focused and competitive.

Stephen will be speaking at the Industry 4.0 Summit. Here he shares his insights into 4IR and its implementation in the UK.

Video:

The Importance of Manufacturing

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industry 4.0 Issue no 7 - DECEMBER 2018

Interview with Stephen Phipson CBE

What is your advice for manufacturers trying to make the most of 4IR? “The best advice for UK manufacturers would be to start now or be left behind. 4IR aims to improve productivity and competitiveness and is already happening across Europe. Those countries already embracing 4IR are years ahead and UK manufacturers cannot afford to fall further behind their international counterparts.”

How should the UK take advantage of 4IR during this period of uncertainty?

“For the UK to take full advantage of 4IR and transform the manufacturing sector, multifaceted support from government, industry and other supporters of the sector is needed to overcome these barriers.

“4IR enhances knowledge of machine uptime, reduces the likelihood of products discarded due to error, and increase the amount of work carried out in a set space of time. The benefits that industrial digital technologies have to offer are limitless.

“Although the UK is the 9th largest manufacturing country in the world by output, the country’s productivity performance has flat-lined over the past decade. If the UK is to continue to hold its own on the world stage in this period of uncertainty, the manufacturing sector requires a business environment that is primed to help improve this performance. 4IR plays a key part in increasing productivity.”

How can Government contribute towards a successful adoption of smart technology and communication in UK manufacturing?

“There has been positive progress from government in recent months that contribute towards successful adoption and integration of smart technology and practice. Such progress can be seen in steps towards delivering the full fibre digital infrastructure that 4IR will depend on, the Made Smarter report, and the resulting Made Smarter Commission.

“Opportunities through schemes and bodies such as the High Value Manufacturing Catapult and the Industrial Strategy Challenge Fund (ISCF) are vital in the quest to usher in successful adoption of smart technology and communication in that they help to address a lack of understanding that industry may have on the benefits of these technologies and how they can be applied to individual businesses.

“The Made Smarter funding challenge in the next round of ISCF that government recently announced presents a welcome opportunity for industry to perform funded research to progress 4IR in the UK, and to develop new methods of improving manufacturing productivity.

“Whilst progress has been made, government can still do a lot more to contribute towards successful adoption, particularly in the area of skills. The 4th Industrial Revolution is developing more rapidly than other industrial revolutions have, and the skills necessary within the workforce will evolve quickly. To meet the demand for relevant skillsets, government must deliver a skills system that ensures lifelong learning and retraining.”

Video:

EEF – the manufacturers’ organisation discuss leadership and skills 10

Interview with Stephen Phipson CBE

Issue no 7 - DECEMBER 2018

industry 4.0

If integration is key, how can it be achieved in both small and large facilities?

“For integration to happen successfully, manufacturers need to know what will work for them in their businesses. Those currently on a 4IR journey need to share best practice of what has and hasn’t worked for them. Sharing information and best practice is important to help to develop the normalisation of automation, and for both small and large facilities to learn from the experience of others.

“The basis for successful integration also lies within the culture of the adopter. A comprehensive approach towards innovation is needed so that it is embraced by all within the business. Setting the culture for successful integration of industrial digital technologies can be done through actions such adopting a visionary approach to leadership and giving IT a more strategic business planning role.”

Is 4IR more about the technology, or the way it is used?

“Advances in innovation and technology allow the possibility of using these technologies in a way that makes every step of the manufacturing process more efficient and productive. Successful application of the technology cannot be done without the foresight of those choosing the right solutions for their business, educated analysis of the data that 4IR solutions may present, or a desire for those involved in the company’s 4IR journey to embrace it as a continuous and progressive direction for the company.”

AI, robotics and cobots are here to stay. What is the role of the human workforce and what can be done to retrain and redeploy?

“AI, robotics and cobots are indeed here to stay and will change the way in which the workforce operates. Whilst the often repetitive and low value parts of some existing roles may be automated, this automation will free up the time of workers to perform the more skilled aspects of their roles to provide more value. Additionally, the introduction of new products and the adoption of new technologies and techniques will mean that certain roles will be increasingly sought after. Roles such as data analysts, scientists, architects, engineers, cyber security engineers and many others will be in greater demand.

“In order to meet the skills demand, government must ensure that lifelong training opportunities must be available. When implementation of the National Retraining Scheme begins next year, it should place increased focus on employees within the existing workforce to up-skill and re-skill in a way that can help them to develop the skills needed in the future workforce.

Government should also use technology to successfully deliver flexible ways of learning that both employers and employees demand, as well as ensuring that future skills are embedded throughout the education curriculum.”

What is your vision?

“As manufacturers integrate more into the 4th Industrial Revolution, there the use of industrial digital technologies and techniques in manufacturing will boost productivity and optimise the use of resources across the industry.

The skills of the UK workforce, particularly in the manufacturing industry will also evolve, as demand is created for many, often high-skilled and high-paid job roles.

The improved communication between systems will allow for increased cooperation and integration with supply chains, better tracking of assets and integrated business planning and production.”

Find out more: www.eef.org.uk www.linkedin.com/company/eef www.twitter.com/eef_insights 11

5 Product Design Trends to Keep an Eye on in 2019 Dave Grammer, VICE PRESIDENT, UK & Nordics, PTC Rapid advances in technology mean that the people behind the scenes need to make sure that the practices they engage in are keeping up. Individuals who focus on product design need to be sure that they are staying abreast with the latest capabilities and trends: whether that means leveraging new technologies such as additive manufacturing or digital twin or improving collaboration to improve the product development process.

Video:

Industry 4.0 TV Talks To PTC At The IoT Solutions World Congress, Barcelona

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5 Product Design Trends of 2019

Issue no 7 - DECEMBER 2018

industry 4.0

Here are five of the top trends in product design that engineers are going to be seeing in 2019: 1

Digital Twin and the Digital Thread

The terms “digital twin” and “digital thread” have been bandied around for a while but in 2019, most engineers are going to see both concepts in action every day. By combining the digital definition of a product with the physical experience of the asset in the field, manufacturers will have a complete digital record of a product throughout its entire lifecycle that can be leveraged to improve the product design, ensure that all legal and security regulations and requirements are being met, and to improve efficiency and serviceability.

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With a digital thread of information feeding back into product design, engineers will finally be able to “talk” to their products and answer some of their most burning questions. Whether they’re determining how well the product is functioning in the field or trying to identify which features and functions of the product customers are actually using, the digital thread of information coming back to form a complete digital twin will allow engineers to close the loop in the product lifecycle.

Breaking Down Barriers Between Engineering and Manufacturing

Manufacturers are increasingly realizing that engineering and manufacturing are working in silos… to the detriment of the organizations.

Because of these silos, engineering and manufacturing are disconnected: engineering passes information on to manufacturing when the designs are finalized and then shares changes to the design when they are implemented. Although this sounds straightforward, waiting for engineering to

completely finish their part in the product lifecycle delays the prework that manufacturing can get done. In addition, small changes by the engineering team can have a large impact on production. With automated manufacturing process planning, the production team can get a head start on what they need to do and automatically see the most up-to-date product information – decreasing the time-to-market and reduce costs associated with rework.

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industry 4.0 Issue no 7 - DECEMBER 2018

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Augmented Reality for Enterprise Visualization

The way that designers view the product has seriously evolved: from 2D drawings on paper to 3D CAD models on a desktop screen, designers are always looking for an easier way to accurately view a product before a prototype has been built.

Augmented reality (AR) is the next evolution of enterprise visualization. AR is a more natural way to interact with a product versus 2D and 3D, as it provides context to a product and data. With AR, there is an ability to superimpose the digital representation onto a physical asset once it has been produced to compare the configurations of the product through its evolution:

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5 Product Design Trends of 2019

whether that’s “as-designed”, “as-built”, “as-manufactured”, or “as-serviced”. AR makes it possible for a new product to be visualized in a real-life setting -- such as the factory floor – at scale. Once there, stakeholders can interact with the data, getting under the hood and viewing the product from views that aren’t easily accessible in 2D or 3D visualization.

Whether it is used for service procedures, manufacturing work instructions, or by sales and marketing to promote new product options or additions to existing products, AR will make it easier than ever to bring products to life.

Additive Manufacturing

In the past few years, 3D printing technologies have surpassed the limits of prototype production and have achieved the quality and scalability needed for industrial use – which we call “additive manufacturing”. This technology trend has overcome the hype and shows tangible benefits in multiple use cases ranging from ultra-lightweight high-end parts for airplanes to cost-efficient mass customization of consumer products. Entire industries, like hearing aids and dental implants, have already switched to being almost 100% 3D printed. However, the true disruptive potential of additive manufacturing lies in the digital transformation of the product engineering and manufacturing process. Gone are the design constraints of conventional manufacturing methods – the expensive and time-consuming tooling before even one part can be produced.

Gone are the challenges of managing the supply chain and logistics.

Because of these advantages, additive manufacturing becomes the optimal production technology in a continuously increasing number of situations, despite the still high cost for material and production equipment. Lowvolume production during the introduction of a new product, replication of hard-to-source spare parts, distributed or local manufacturing in emerging markets… these are just some of the examples where additive manufacturing can yield benefits – even for lower-complexity parts.

And new technologies, such as metal binderjetting, can further increase production speed and efficiency.

Issue no 7 - DECEMBER 2018

5 Product Design Trends of 2019

industry 4.0

Video:

Industry 4.0 TV Talks To Sylatech At The TCT Show, Birmingham

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The Year of the App

We’ve all been ruled by apps on our smartphones and tablet devices for years. Pretty much every company that provides a service to consumers has an app: whether it be Facebook or Bank of America. For the most part, though, these apps are coming from companies that are business-toconsumer. In 2019, we will start to see businessto-business companies provide apps to their customers as well.

With apps for their enterprise systems, manufacturers will be able to quickly access important product and enterprise data on the fly, in a format that is easy for them to understand.

Products with sensors that feed information from the field back to the factory floor can be connected to apps that enable stakeholders to quickly and easily view real-time information.

Here is another way that AR can be leveraged: with AR apps, global teams can quickly review designs or prototypes concurrently. The possibilities of enterprise apps are endless, and they will enable users to quickly and easily launch a system that has traditionally been tethered to a desktop.

2019 is posed to be an interesting year for product design. With new capabilities such as additive manufacturing, the digital twin, digital thread, and enterprise system apps, improved enterprise visualization, and better collaboration between engineering and manufacturing, product design teams will be able to work both faster and smarter.

Find out more: www.ptc.com www.linkedin.com/company/ptc www.twitter.com/PTC 15

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Contact Gary Gilmour, Event Director +44 (0)1642 438 225 info@industry40summit.com Contact Gary Gilmour, Event Director | +44 (0)1642 438 225 | info@industry40summit.com

Call for Entries to new

ÂŁ2,500 Student Digital Innovation Competition The Digital Innovation Challenge is now open for entries.

Students from around the world are invited to submit their Industry 4.0 solution ideas for a chance to win a cash prize of ÂŁ2,500, awarded at the Industry 4.0 Summit in Manchester.

The Digital Innovation Challenge seeks to find innovative Industry 4.0 applications that can be developed for industrial use. Entries are invited from student teams of up to six people. At least 50 percent of the team must be either current students (undergraduate or postgraduate from any Higher Education Institution) or have graduated after June 2014.

The teams behind the shortlisted entries will have a chance to present their ideas at The Digital Innovation Challenge Finals at the Industry 4.0 Summit, which runs in Manchester over the 10th and 11th April, 2019.

How to Enter the Competition Format The judges are looking for an outline of an innovative solution to a real Industry 4.0 challenge.

A panel of judges will shortlist 10 finalists who will be invited to the second round.

The final pitch will consist of a 10-minute presentation followed by 5 minutes of questions from the judging panel. The presentation can be in any format. A table, projector, mic and laptop will be provided.

Submission details Applicants must submit a 250-word summary and a 30 to 60 second video promoting their solution.

Competition Schedule Competition opens: 5th Dec 2018

Finalists will be announced: 15th Feb 2019

Submission deadline: 30th Jan 2019, 23:59

Finalist Presentations: 10th – 11th Apr 2019

To participate in the challenge contact: C.Diver@mmu.ac.uk 17

industry 4.0 Issue no 7 - DECEMBER 2018

Digital Innovation Competition

Video:

Students create 3D Printed robot prosthetic limb for amputees

Last Year’s Digital Innovation Challenge Winners The 2018 winning team of student innovators came from the University of Manchester and was led by Alex Agboola-Dobson. Lead electrical engineer, Sebastian Preston-Jensen, lead software engineer, Panagiotis Papathanasiou, and mechanical and software engineers Maximillian Rimmer and Shao Hian Liew completed the team.

Together, the student engineers created a 3D-printed robotic prosthetic hand. What attracted the judges to the team’s innovation was the potential of its solution to dramatically change the cost of functional robotic prosthetics.

Traditional robotic hands with basic multi-grip functionality start at £3,000.

By contrast, Agboola-Dobson’s team’s robotic hand featured fully posable joints, with each finger and the thumb being able to move as well as make a fist. This meant it could be used for picking up items, using a knife and fork, typing, opening doors – and even playing rock-paperscissors.

Advanced robotic prosthetic limbs with this sort of functionality currently cost upwards of £25,000; rising to £60,000 when bought privately.

Agboola-Dobson said, “Some traditional prosthetics can both look and feel cumbersome or, those that don’t, are extremely expensive. We think our design can really make a difference and we will be looking to commercialise the project in the future.”

The team’s use of Stereolithography (SLA) printing, which uses high-quality resin plastic production, enabled the students to build the hand for just £307. Eventually, the team hope to move to Fuse Deposition Modelling (FDM), which will allow the hand to be produced even more cheaply while retaining its quality and functionality.

The prize money of £2,500 is now enabling the team to develop their idea further.

Find out more about last year’s winning entry: www.manchester.ac.uk/discover/news/studentscreate-3d-printed-robot-prosthetic-limb-for-amputees 18

Digital Innovation Competition

Issue no 7 - DECEMBER 2018

industry 4.0

Video:

Siemens Global University Challenge 2018

Future Innovators: Automation Meets Edge Manchester engineering students Thomas Kendall and Kai Chong Sim make up another team of promising and award-winning students.

Kendall and Sim entered the Siemens’ Global University Challenge “Automation meets Edge”, an open innovation contest held by Siemens with the aim of encouraging students to develop solutions to meet the challenges of industrial production.

Entries were submitted by 55 different teams of contestants from all over the world and Kendall’s was one of ten shortlisted ideas chosen by judges to be taken forward to participate in a Hackathon at the Siemens Factory Automation Business Unit in Nuremberg over the week of 8 – 12 October 2018.

Kendall likens his solution to “a Google Street View for your factory”. Using a Siemens IoT2040 Gateway and open-source software, data charts and analytics could be accessed via a web app.

Kendall said, “The app allows you to visualise the entire factory without the need to be there, and links in features for purchasing and uses live data for maintenance instructions, user training and operational instructions.”

Having made the final ten, Kendall won €1,000 prize money. He is full of praise for the competition; highlighting the benefits of academia and business working together.

“Universities are idea factories; they have a wealth of talent who are constantly bringing fresh, outof-the-box ideas to tackle industry problems.

Academia is not tied down to a specific way of thinking, a specific discipline or a specific area of industry. Ideas from civil engineering, aerospace, textiles, fashion, material science can be transferred into a problem in mechanical engineering, for example. With industry moving so quickly, academia has the people and the problemsolving potential to keep up,” Kendall said.

“There is mutual benefit in Academia and industry collaboration. The students left having been mentored by industry professionals, having used cutting-edge industrial equipment focused on industry problems. On the other side, Siemens left with a wealth of ideas in massively different areas, feedback from developers and engineers, and the potential of new collaborations.”

Find out more about Siemen’s Global University Challenge: www.siemens.com/press/en/pressrelease/?press=/en/materials/ mediaservice/2018/2018-10-08-university-challenge.htm 19

industry 4.0 Issue no 7 - DECEMBER 2018

Digital Innovation Competition

Future Innovators: Student Employee of the Year Elen Parry completed a three-year BA in three-dimensional design at Manchester Metropolitan University’s Manchester School of Art in 2018 and is now taking Manchester Metropolitan University’s new MSc in Industrial Digitalisation.

While studying for her BA, she applied for work through the University’s job service and obtained a job as 3D print room assistant at the PrintCity innovation centre.

PrintCity is Manchester Metropolitan University’s Industry 4.0 hub specialising in printing and digital manufacturing. The centre’s manager, Ed Keefe, nominated Elen for the Student Employee of the Year award because of her attitude and approach in the workshop and for her impact as an advocate for PrintCity.

Keefe said, “When asked to do something new Elen always responds with a ‘can do’ attitude, sometimes left to her own devices to learn software or figure out how to fix a printer. I can’t recommend her enough for this award, she tackles every problem with a smile and is always pleasant to be around. She has a great career ahead of her.”

Elen commented, “The job started with a placement and I learned so much from the placement and enjoyed it so much, and got on with the work so well, that they offered to employ me part-time while I was still studying. Through the job I have had the opportunity to work with external clients, live projects and the kind of things I would be doing in the real world.”

Professor Craig Banks, academic lead for PrintCity, praised Elen and highlighted the journey she has been on through her work at the centre.

“It is an amazing journey that Elen has been on, from arriving in PrintCity not knowing what CAD was through to embracing the technology within her course to becoming an expert and teaching the future CAD experts… It is amazing how far Elen has come in such a short space of time and in recognition of her ability she was appointed an Autodesk Student Ambassador for the UK.” As an ambassador for Autodesk, and the first recipient of its Women in Leadership scholarship at Manchester Metropolitan University, Elen was invited to participate in Autodesk’s Design Slam in Copenhagen.

As one of a pair of students representing the UK, Elen was given a brief to design a spacecraft from scratch using Autodesk’s Fusion360 software. The winning pair were decided based on which team’s design received the loudest cheer from the audience, as measured on a decibel recorder. Elen and her partner triumphed and, as a result, she was invited to be an Autodesk guest at the Autodesk University in Las Vegas this November.

Find out more: www2.mmu.ac.uk/news-and-events/news/story/8079

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How Can SMEs Leverage the Potential of 3D Printing?

What potential does this key Industry 4.0 technology have to offer SMEs? Industry 4.0 Magazine talks with two 3D printing businesses – both SMEs themselves – to understand how SMEs can leverage the potential of additive manufacturing.

Video:

Part for a Laser Printer Sheet Feeder Pickup Assembly

Of all the technologies that fall under the Industry 4.0 umbrella, 3D printing is probably the most accessible: the tangible, highly visual nature of the technology enables people to connect with the concepts involved easily.

However, Kevin Askew of Yorkshire-based 3D print specialists GoPrint3D warns this can be a double-edge sword. “It can be tempting to see 3D printing as easy, but a 3D printer isn’t like a desktop inkjet printer. You need to get the right machine and the right advice – and the advice is as important as the machine.”

Askew knows this from experience – GoPrint3D grew out of a traditional print business that began looking into 3D printing for its own use.

The possibility of printing replacement parts internally was attractive, but the reality was a steep learning curve.

“We didn’t have the best experience initially,” Askew explains, “And we felt we could do a better job of supporting customers. We could apply what we had learnt to advise customers on the best machines for their job.”

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industry 4.0 Issue no 7 - DECEMBER 2018

the Potential of 3D Printing

Video:

Industry 4.0 TV Talks To Tri-Tech 3D At The TCT Show, Birmingham.

Engaging with the Right Advice Fast-forward six years and GoPrint3D is now providing consultation, sales and warranty repairs for businesses and 3D printer suppliers across Europe. It is the supplier to Print City, an Industry 4.0 initiative at Manchester Metropolitan University.

As well as creating a centre for excellence in the North West of England, Print City offers a new environment in which SMEs can engage with 3D printing, Askew says. Students can assist with 3D design in a mutually beneficial partnership; the business can access the skills it needs, and the student gains essential commercial experience.

Consultation is a big part of GoPrint3D’s own offering and, as such, it does a lot of work with the national STEM centre in York; helping to advise schools and education leaders.

“Lots of people engage with us initially to use our bureau services,” Askew explains, “If people start with an idea, we can produce samples for them and this provides an opportunity to benchmark and test ideas. There’s always a trigger; we just need to understand what that trigger point is – then we can help the business find out whether 3D print is a viable solution.”

Why Consider 3D Printing?

Askew suggests several different reasons for exploring the potential of 3D print:

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Product design and the speed of iteration

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bility to easily and cost-effectively A manufacture short runs

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Better management of the supply chain

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Reducing lead times

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he potential of customisation for customers T – helping to build loyalty

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Huge cost savings

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Extending the life of legacy equipment.

New product prototyping is one of the most obvious and common applications, says Daniel Abram of 3D Print specialists 3DGBIRE. “Imagine for many businesses the cost of a prototype is £10k or more,” Abram says.

“Compare that against the cost of a 3D printer – maybe around £5k – and from that you can print hundreds of prototypes.”

the Potential of 3D Printing

Issue no 7 - DECEMBER 2018

industry 4.0

“Printing coloured layers can help to indicate wear.

For example, if you have a blue part and you see a red layer showing through, an operator can see it is time to call maintenance.”

Kevin Askew, Business Development Manager, GoPrint3D

Extending the Life of Legacy Equipment Parts replacement is another accessible entry point for SMEs; it’s what drove GoPrint3D’s own first forays into 3D printing. It seems somewhat ironic that the poster-child technology of Industry 4.0 is being used to extend the lifecycle of legacy equipment, but Askew is adamant that this is one of the most valuable reasons for SMEs to initiate a 3D print programme.

He cites the example of a confectionary business that wanted to replace arms on a machine on its production line. Previously made of cast metal, the new 3D-printed part was infused with Kevlar. Using 3D print reduced the cost of part production from £500 per set to £60 per set.

The direct cost savings were just a small part of the benefits gained, however. The weight saving has minimised the maintenance required on the gearing behind the machines – reducing the time spent on maintenance and the downtime of the machine. Most importantly, it has removed the risk of contamination by using non-greased bearings in the 3D-printed part – a key benefit for the food manufacturer.

Printing replacement parts has particular value for old and unsupported equipment for which replacement parts are hard to find. Abram makes the point that companies such as Samsung are beginning to make 3D-print design files available to customers, especially as the machines reach end of life. This way, customers can print replacement parts as they need them.

For the customer, this prevents time being wasted searching for hard-to-find parts and extended delivery times. It also makes it less likely equipment will need to be retired when parts become obsolete. Suppliers also benefit because they no longer need to hold inventory or schedule short runs of little-used parts.

Not Straight Replacement – but Optimisation At the same time as extending the life of a machine, Askew argues, 3D print gives SMEs an opportunity to not simply to replace a part but to improve the part.

“We can embed components into legacy parts; so when you change a part you can swap it for a 3D-printed ‘smart’ part. Next time you come to change it, you can replace it before it breaks.

You don’t even need to embed sensors: even something as simple as printing different layers can make a huge practical difference.

Printing coloured layers can help to indicate wear. For example, if you have a blue part and you see a red layer showing through, an operator can see it is time to call maintenance.

You have an opportunity to change the part before the line stops.”

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industry 4.0 Issue no 7 - DECEMBER 2018

the Potential of 3D Printing

If at First You Don’t Succeed…

While there are a multitude of opportunities for SMEs to benefit from 3D printing, SMEs shouldn’t underestimate the initial lead time of a project.

“There will probably be lots of iteration,” agrees Askew. “They’ll probably fail on the first part.

But continue and you will succeed. And once you get going, you’ll find you are printing all kinds of things. In the last week, our team have printed – just for our own use, because they can – a wrench to open a barrel and a TV rack for a display.”

The main barriers to entry are cost, a lack of CAD skills, and education about 3D printing.

However, Askew makes the point that the cost of the machines are usually dwarfed by the cost savings they can deliver.

He cites the example of a hand-held tools manufacturer who has gained a parts saving of £26k a year by printing a single 3D-printed part.

The savings the company has realised have started it on a journey to explore other ways to use 3D print.

“Sometimes it’s not always feasible to 3D print something because of the material,” says Askew, “But usually we can work with the customer to find an alternative material. That’s about asking the right questions: why are they using it? What properties are important? Does it need heat resistance or resistance to particular chemicals or a particular strength?”

How to Get Started Daniel Abram at 3DGBIRE makes the point that one of the biggest barriers for SMEs considering 3D print is the sheer variety of machines available. “The success of the technology is also one of its main barriers – customers are overfaced with which machine to buy,” he says.

“My main advice for SMEs is to do the research on the machine,” continues Abram. “There are a lot of machines and you need to pick the right one for your particular needs. You need to focus on a single business case and focus on that alone when you make the purchase. It’s easy to get excited and start printing things for which there isn’t a business case.

“Understand that you won’t have all the answers about what the machine will be used for in the long term… You need to focus on the single business case initially. Later, you can be open minded about what the machine can do for your company.”

Daniel Abram, General Manager, 3DGBIRE. 24

Understand that you won’t have all the answers about what the machine will be used for in the long term. You will find other opportunities – typically, customers start with just one requirement but end up finding 25 more. You need to focus on the single business case initially. Later, you can be open minded about what the machine can do for your company.”

Issue no 7 - DECEMBER 2018

the Potential of 3D Printing

industry 4.0

Industry 4.0 and The Future of 3D Printing The debate around Industry 4.0 is encouraging increasing numbers of SMEs to investigate what 3D printing can offer – whether through initiatives led by education, like Print City, or through government-led initiatives such as Digital Catapult and the Made Smarter pilot.

The increasing awareness around the Industry 4.0 agenda is noticeable, says Askew. “Four or five years ago, at Trade Shows people would be asking what 3D print is and why we were there. Now there is a maturity in the market – people are bringing parts with them to the trade show and asking, ‘can you do this?’. Perhaps they have a need, but they aren’t sure which technology to go for – powders, plastics, metals or ceramics… people just want advice.”

Askew thinks the biggest change 3D printing will bring in the near future is a move to digital stockholding.

This is already happening because of the opportunity 3D printing offers to streamline every part of the supply chain with mutual benefit to suppliers and customers.

However, Askew says in the long term the biggest impact of 3D printing will be in design – and that is yet to be felt.

Abram agrees; “When a 3D printer can create a decent PCB, then things will really change – we’re not there yet, but I can see that we’ll start to get some very different design; really organic shapes… people are only just beginning to wake up to the potential.”

Find out more:

GoPrint3D is an ISO-9001-certified supplier of 3D printing technology, consultation, bureau services, warranties and repairs.

Established in 1988, it now supplies and supports a range of 3D printing technology products from more than 12 manufacturers across the UK and Europe.

3DGBIRE provides 3D printers, scanners, filaments, spare parts, training and service plans for the desktop 3D printer world, including the Ultimaker range of 3D printers. Its range also includes Photocentric 3D Printers, Raise3D Printers and Sicnova Industrial 3D Printers.

College Business Park, Kearsley Rd, Ripon HG4 2RN.

Chorley Central Business Park, 2, Chorley, PR6 0BL.

+44 (0)1765 694007

0800 772 0257

www.goprint3d.co.uk

www.3dgbire.com

www.linkedin.com/company/goprint3d

www.linkedin.com/company/3dgbire

www.twitter.com/GoPrint3D

www.twitter.com/3DGBIRE

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industry 4.0 Issue no 7 - DECEMBER 2018 ANT service & 24/7 support

ANT Analysis & general implementaion idea 6

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The ZEISS Quality Network offers a strong partner network for generating, networking and interpreting quality data; whether at your suppliers’ facilities, in the measuring lab or in a highly automated manufacturing environment. This solution is compatible with quality and manufacturing data from throughout the production process, including third party systems.

ZEISS’ Quality Intelligence Portfolio of IoT software products also allow users to view production facility results from a mobile device in real-time. This enables customers to steer their processes more effectively and identify currently untapped process and quality potential. The system uses a cloud-based computing application that allows results to be accessed from anywhere and everywhere. OEMs can monitor suppliers’ processes as it happens, allowing ZEISS to access critical data quickly and easily, enabling them to make real-time changes to the process.

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