Smart Furniture Production 2021 by Gearing Media Group Ltd

Smart Furniture Production

June 2021

A FURNITURE & JOINERY PRODUCTION SUPPLEMENT

OUR WOODWORKING TECHNOLOGIES, YOUR VISION Simplify work and improve performance with the widest range of woodworking solutions. Flexible and modular machines and cells, integrated with state-of-the-art systems and automation, such as anthropomorphic robots, cobots and autonomous mobile shuttles. Smart technologies to increase efficiency and flexibility, reduce scraps and waste, optimize the quality of your products with the latest software and digital services. A human approach to help you achieve your vision, with a team of specialists always ready to support you, even from afar. SCM: your Smart and Human Factory.

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info@media66.net EDITOR John Legg Tel: 01424 834973 john@media66.net Twitter: @FurnitureProdEd ADVERTISING MANAGER Lisa Williams Tel: 01424 834829 lisa@media66.net PRODUCTION James Ash studio@media66.net DIGITAL CONTENT Nyall McCurrach digital@media66.net COPY ADMINISTRATION & DATA Steve Merrick Tel: 01424 776108 production@media66.net ACCOUNTS Wendy Williams Tel: 01424 774982 accounts@media66.net SUBSCRIPTIONS UK-£65, Europe-£85, RoW-£95 lisa@media66.net PROOF READER Paul Farley REPRO, PRINT and DISTRIBUTION Stephens & George DISCLAIMER: All material submitted for inclusion in Furniture Production is done so entirely at the contributor’s own risk. No responsibility is accepted for the safe-keeping of contributors’ materials. Whilst all attempts are made to ensure accurate reproduction, Furniture Production accepts no responsibility for variations. Artwork undertaken by our studio remains the copyright of Media66 and may not be reproduced or stored without prior permission. Some articles in Furniture Production have been submitted by companies and organisations. Monies may have been accepted in some instances to offset production costs. All rights reserved. In respect of artwork originated free of charge as part of a booking, clients should know that excessive work (more than one set of corrections, known as ‘authors corrections’) is chargeable at £55 per hour. DATA PROTECTION “OPT OUT” STATEMENT: Readership data held by Media66 may be shared with any member of the Media66 and associated companies for the purposes of customer information, direct marketing or publication. Data may also be made available to external parties on a list rental/lease basis for the purposes of direct marketing. If you do not wish data to be made available to external parties for list rental or lease please write to: Data Protection Co-ordinator, Media 66 Ltd, 36 Stirling Road, Castleham Business Centre East, St Leonards-on-Sea, East Sussex TN38 9NP. SUBSCRIPTIONS: Refunds on cancelled subscriptions will only be provided at the publisher’s discretion, unless specifically guaranteed within the terms of the offer

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Content 4 Made Smarter demonstrates how it is helping furniture and joinery businesses to engage and adopt high-tech, smarter technologies 6 Jake Athey tells us how Widen Collective stepped to answer Suncast Corporation’s need of a smart solution for its image library 8 Nexer’s Colin Crow advises how important top-to-bottom support is when embarking on a digital transformation 12 Biesse’s SmartAction concept provides a complete Smart Factory solution to companies of any size 14 Major hinges and ironmongery firm, A Perry, can now process orders much quicker after considerable investment in automation technology 18 Moving beyond traditional automated systems, SCM’s impressive digital and smart factory is still user-friendly, designed to satisfy the challenges of mass customisation and Industry 4.0 even more effectively 22 Labelling tech experts, Zetes and ZetesAtlas, have enabled Norbord’s Genk, Belgium operation to keep on top its logistics – a smart solution indeed, bearing in mind the factory’s considerable output, which requires some 1400 labels to be applied 23 Looking to invest in a smart and flexible edgebanding solution that offers some impressive Industry 4.0 credentials? Holz-Her’s patent-protected Glu Jet system has you (and your edging) covered. With over 50,000 units sold worldwide, we take an closer look on pages 24-25 at why Holz-Her’s patent-protected Glu Jet system is such a popular solution for making ultra-thin glue joints achievable when using both PUR and EVA 26 We catch up with Martina Schwarz of CAD+T Consulting, who says that we should embrace technology and digitalisation – it’s no longer a question of if companies need to integrate intelligent technology into their business, it’s when 28 We take a look at Gripple Automation, which has expanded rapidly in recent years and has now taken on new staff and a larger premises in Sheffield 30 See the quality of the Pytha 3D CAD system for the woodworking industry, furniture and joinery design, high-end kitchen design and more 32 As industry today strives for more efficiency, increased output and reduced costs, Motion Control Products has introduced the next generation of Elfin series six-axis collaborative robots to support automation 34 We hear from Nigel Hyland at Comau UK – a business whose knowledge of process dynamics and workflow optimisation puts it in a ideal position to help the furniture and joinery industry leverage the benefits of what the company calls “right-sized automation” 38 Mirka shows us its latest robotic sanders and polishers for use in automation 40 ABB unveils its next-generation cobots, which it says are ideal for first-time users 42 Rockwell Automation Inc and Comau are joining forces to give businesses worldwide vital tools to maximise manufacturing efficiencies through unified robot control solutions

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Handrail Creations, a specialist handrail manufacturer based in Bolton, was supported by Made Smarter to invest in 3D scanning and design software to aid its surveying process

Being smart with manufacturing Increasing and accelerating the adoption of technology in manufacturing, especially among SMEs, was one of the key recommendations of the Made Smarter Review, a study by the UK Government exploring why the UK was falling behind in productivity and international competitiveness. It became the foundation of the Made Smarter Adoption programme in the North West. Since 2019 it has worked with more than 1200 businesses, supporting them to introduce digital tools and technologies to help boost productivity and growth, and navigate the impact of Covid-19. More than 600 manufacturers have received intensive support including expert, impartial technology advice, digital transformation workshops to help manufacturers take their first steps to transform their business, a leadership programme, and funded digital technology internships. 154 businesses have secured £3.82m matched funding for 192 projects, leveraging £10.2m of private sector investment. These projects are forecast to deliver an additional £150m in gross value added (GVA) for the North West’s economy over the next three years, create over 920 new jobs, and upskill 1764 existing roles. Some manufacturers are developing projects using technologies which enable them to integrate systems, capture and analyse data, and even create simulations of their plants and processes. Others are using 3D printing, automation and robotics to solve business challenges and meet increased demand.

Over 80% of SMEs working with Made Smarter to adopt cutting-edge technologies have seen a boost in productivity, and more than 25% reduced their carbon emissions. Businesses are also benefiting from increased revenue, profits and exports, and lower energy bills. Manufacturers that have engaged with Made Smarter recognise that digital tools and technology are essential to remain competitive and efficient. But there is uncertainty of where to start, and a struggle to find the time to capitalise on opportunities. It is clear that the SMEs need specialist advice and insight to help them select the right approach for their business, how much to invest and which technologies will bring the greatest benefits. This is why Made Smarter developed a Digital Transformation Workshop, an innovative, streamlined process which uses a diagnostic of a manufacturer’s products, services, processes and people to find practical solutions to overcome business challenges. The bespoke process cuts through the jargon to provide an honest and holistic view, and demonstrates the steps required in order to achieve digitalisation. It has been designed in a way that requires minimal time investment for manufacturers to turn the actions into results, while still allowing participants to focus on the day-to-day operations of the business. The result is an easy-to-use guide for decisionmakers with recommended first steps, a technology roadmap, and information about how to get further support from the Made Smarter programme.

Multiwood Products, a distributor and producer of kitchen doors and components based in Bury, has benefited from the process and is now investing in new ERP technology to support its new manufacturing requirements. Ben Allan, creative director, says: “The digital transformation workshop helped identify systems and processes that could be improved to help drive the success of the business. “These ranged from continuous improvement methods through to reviewing and introducing new management processes. “Made Smarter also helped create a roadmap that will guide the company towards achieving some of its goals, specifically associated with digitalisation.” Armed with a digital roadmap, manufacturers can grow progressively and sustainably, avoiding the wasted time, effort and money that comes from adopting the wrong technology. Handrail Creations, a specialist handrail manufacturer based in Bolton, was supported by Made Smarter to invest in 3D scanning and design software to aid its surveying process. The business, which has created one-off pieces for clients such as the US Embassy and the Houses of Parliament, believes the adoption of the new technology will accelerate its process by +25%. Kenny Macfarlane, MD, says: “While the new equipment will speed up the scanning process and reduce survey time, the real benefit will be in the processing speed, converting the data into something that is usable for our design team. “With more than 100 live projects being managed at any one time and 75% of surveys

done using a 3D scanner, we are looking at saving a lot of man hours. “It will increase our efficiency, but more importantly it will reduce the chance of error, ensuring that our bespoke products are right, first time.” James Tanner Joinery, a manufacturer of hardwood and softwood products used in the commercial and private sectors including bespoke sash windows, doors and staircases, engaged with Made Smarter to overcome a major challenge which was restricting production capacity. The Kendal-based business adopted an Industry 4.0-ready, five-axis CNC machine and software to remove labour-intensive processes and link to a new cloud-based design software, which tracks the life journey of the product from customer enquiry, design and prototype using fully rendered 3D imaging, material management, to manufacture and delivery. With the new technology, a window that took 60 minutes to machine now takes four and a half minutes – 13 times quicker – with a higher level of accuracy. If one takes into account the new design process and software programming, job time is expected to reduce by -50%. The solution offers predictive maintenance, live and historical data analysis, downtime analysis and cloud-based data storage with remote access. James Tanner, MD, says: “Having a complete overview – which can be monitored remotely – is game-changing for us. Having time management for jobs will show gaps in production and enable the most efficient use of the machine and staff. “By doubling its production capacity, the business can then take on that extra commercial work.” But beyond the profit, James is as excited by the benefits in accuracy. “Our motto has always been ‘precision-made joinery’,” James says. “Accuracy is really important to me, to the reputation of this company. There’s not a ‘good enough’ with me. Our work must be an engineering standard, which is very difficult using wood. This new solution takes our ability to achieve that accuracy to the next level.” “Now we have taken this first step, I can see

James Tanner, MD of James Tanner Joinery

the possibilities. And that is very exciting.” Before implementing any game-changing technologies and solutions, manufacturers need to consider whether they have a culture of innovation, the right skillsets, good digital leadership, and the buy-in and support of the team. The Made Smarter Leadership Programme was designed to equip SME managers and directors with the strategic view and the skills needed to pursue smarter manufacturing. Using a hybrid model of classroom learning and site visits, executives are readied to start their business transformation. The programme allows leaders to take time out of their business to reflect on the bigger picture and share ideas and experiences alongside their peers in manufacturing. This will help them return to their business and develop a digital strategy – which has been identified as something many businesses lack, yet it is essential to create growth and efficiency. Made Smarter is also supporting manufacturers with organisational and workforce development (OWD), an essential tool to successfully implementing emerging technologies into a business. Fully-funded, specialist advice focuses on getting a business ready for industrial digital technologies by analysing the structure, identifying if departments could work better together, and if there are any gaps in knowledge where upskilling could help, before supporting with the practical planning, developing people, engaging with employees, and producing materials that can be used to develop a highly skilled, flexible and productive workforces needed to capitalise on digital transformation. Made Smarter has also helped SME manufacturers tap into digital talent. Its fully funded Digital Technology Internships enable undergraduates, Masters and PhD students, and graduates the chance to work on live projects which may involve implementing technology projects, upskilling staff or helping develop the business’ digital roadmap to support its digital transformation. Crystal Doors, a manufacturer of bespoke, vinyl-wrapped furniture components based in Rochdale, tapped into this element of the programme, taking on Lewis Cookson, a

graduate in BSc Computer Science & Digital Forensics from Northumbria University. Lewis has been supporting the implementation of a data and systems integration project which will establish a network of sensors connecting the company’s machines through the cloud onto a dashboard. This will enable Crystal to gain insights into how its machines are performing and identify potential efficiencies. Ben Horn, digital transformation programme manager, says: “Our digitalisation plans are ambitious and will introduce technologies and concepts that are brand new to the workforce. The cultural change has to be handled properly. We don’t want anyone left behind, so the training and transition needs to be as easy and intuitive as possible. Upskilling our staff is key to its success. “By bringing on Lewis through Made Smarter we have doubled the pace of the transformation. His input has been incredible and an injection of rocket fuel into our project.” Lewis, 23, says: “Crystal Doors has some very exciting plans for the future, and it is fantastic to be part of that journey, capturing and displaying real-time data analysis for the first time, supporting the betterment of the company, and playing a role in reducing carbon emissions. “It is exciting for me to be able to take my specialism and skills and apply them to a reallife situation and see the results. The progress we have made so far eclipses everything that has been achieved in recent years. We are making great strides.” These examples show just how important emerging technologies like data and systems integration, robotics and 3D printing are to the future of furniture manufacturing, and how a holistic approach to digitalisation is helping businesses move forward with confidence. Such has the been the success of the North West programme, it has been expanded to the North East, Yorkshire and the Humber, and the West Midlands regions, meaning more manufacturers can access support to adopt digital tools which will increase their growth, productivity, efficiency and create high-value, well-paid jobs of the future. www.madesmarter.uk

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How Suncast streamlined its asset distribution and embraced the future of digitalisation

By Jake Athey, VP of marketing and customer experience at Widen

Furniture images: © Suncast Corporation

Suncast Corporation is a leading US manufacturer of home and commercial products, specialising in outdoor furniture, storage, and garden products. It regularly shares product imagery with internal and external stakeholders at all points within the content lifecycle. Suncast designs, develops, and manufactures a wide range of home and commercial products which require a significant amount of productrelated digital assets in order to go to market. These assets range from studio and environmental photography to 360° imagery, product information PDFs, and packaging graphic PDFs. These files are then used to create final deliverables including packaging and presentation materials, customer websites, and advertisements. With so many assets and file types, Suncast needed a place to store them all, so turned to its file directory system to organise its digital assets. In doing so, however, access to assets was limited for employees, resulting in long

approval processes and an inefficient search and distribution workflow for assets. “There were a lot of large image requests that fell on our department, and looking through folders to find them was time-consuming,” shared Ed Cange, senior marketing manager at Suncast. The solution With its current filing system proving inefficient, Suncast decided to invest in a digital asset management (DAM) platform to make marketing content easier to retrieve, organise, and distribute. Its search for a DAM solution led Suncast to the Widen Collective, which it selected to help meet the manufacturers three key objectives –improve file searchability, provide self-service access to assets, and streamline its distribution processes. Make searching for assets easy and intuitive The collective provides robust metadata and taxonomy options that give users multiple ways to search for assets and filter results. Suncast

used these options to develop a metadata scheme tailored to its specific content needs and aligned terms with familiar internal language. For example, users are able to search by values such as environment, white sweep, or open inset. They can also search by product type (eg sheds, hose reels, and deck boxes) or categories (eg packaging, marketing copy, and manuals). Searchability was further simplified using spotlight searches on Suncast’s collective dashboard for quick access to popular searches. Improve user experience across all departments In order to streamline processes, the team at Suncast desired to improve asset retrieval and distribution tasks. With the collective’s user-friendly interface, Ed’s team now has an accessible user experience, where it can retrieve and distribute assets with ease. “It is great to be able to send large quantities of images with a link in an email,” says Ed. This

means Suncast saves time on repetitive tasks that it can now dedicate to more valuable work. Provide easy and secure access to assets Not everyone needs to have access to everything – both for security reasons, and searching ease. With the governance tools in the collective, Ed’s team controls the content that is available to each user based on their role and department. “We had our own file system which worked for those in the know, but we needed to allow other departments and partners access to the images, to speed up the process,” he says. With access rights predetermined based on need, teams across Suncast are able to spend less time searching — or waiting — for files, and more time on valuable work. The result With the collective implemented, it is now the go-to repository for retrieving and sharing assets with others. “Timely distribution of

assets is key when projects or requests come in,” Ed shares. Providing teams across the company with secure, self-serve access to content has improved operational efficiency by allowing users to download the content they need when they need it. “We have empowered others to locate images themselves, and alleviated some bottlenecks,” Ed explains. Additionally, not only has the Suncast team improved internal processes, but it has also found a true partner in Widen. Suncast knows the answer to any issue is just a phone call, email, or chat away. “It’s great to know there is a human that you can email or call and get an answer back,” says Ed. Before Widen, Ed and the Suncast team lacked the tools they needed to effectively manage and distribute assets. Now, there is a centralised repository that has improved asset searchability, provides self-serve access, and streamlines content sharing, saving the team time, money, and headaches. www.widen.com

Image © Rawpixel

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Top-to-bottom support crucial for digital transformation success common for businesses to choose the wrong technologies or roll them out without enough support for the employees who use them. When leaders do decide to embrace modern technology, implementing new digital procedures without being fully invested in supporting employees through the transition can lead to problems.

By Colin Crow MD of digital transformation specialist, Nexer

Despite widespread media coverage of the benefits that come with embracing digital technology, scepticism towards complete transformation within manufacturing remains. Digital solutions will only make a tangible difference to business operations and outcomes when used correctly and consistently, demonstrating the need for all employees to believe in them. For digital transformation to truly be a success, buy-in from all levels is essential. The C-Suite must be on board to implement and secure funding for new technologies, and, equally, those who use it on a day-to-day basis must also be convinced of its benefits. A survey of manufacturing business leaders found that less than half (44%) are always open to implementing new business technology, leaving a staggering 56% of senior businesspeople sceptical of the potential business. This indicates that barriers to effective digital transformation within the sector are created by those at the top who are wary of new technology. When asked about opinions surrounding digital transformation, more than a quarter of leaders (26%) said that technology can cause problems if not implemented carefully, 16% believe the cost can often outweigh the benefits, and nearly one in 10 (9%) believe it creates an unnecessary burden on employees. In reality, technology has a proven ability to improve collaboration across a business, enhance real-time business knowledge and data availability, and unlock potential new ways of engaging with customers and markets. The survey data suggests that many senior business leaders have been burned by previous digital transformation effort, as it is unfortunately

Overcoming digital skills Only a third (33%) of businesses surveyed in the Nexer Connected Enterprise report agreed that their employees act positively towards new technology, and only slightly more (37%) said their employees appreciate the benefits of new technology. Low engagement from the day-to-day users of new technology can harm a business’ overall digital transformation progress, as the tech may be used in a less consistently correct manner than it would be by engaged employees. As well as this, there must be an adequate level of consultation, education and support before, during and after the digital transformation process. The demand for this is clear, when considering that just 28% of businesses said their employees find it easy to learn how to use new technologies, 24% said that some of their employees struggle to learn, and 13% said many of their employees find it difficult. Digital skills vary from person to person within a workforce, with younger employees more likely to find adapting to new ways of working easy – though this is not always necessarily the case. It is essential that businesses do not assume a certain level of technological proficiency when

introducing new technologies to employees – particularly for those who have been working for the business or within the industry for a long time. Keeping employees at the heart of digital initiatives To improve the sentiment towards new digital tools and processes among employees, and to in turn ensure optimum return on investment, businesses should always take a collaborative approach, taking time to explain the reasons behind any new introductions to employees and providing as much support as necessary to make staff feel comfortable. Just 12% of businesses surveyed said their employees tell them that their business technologies improve their daily life, and nearly one in 10 (8%) said that they regularly receive complaints from employees following the implementation of new technologies. It is important to bear in mind that while digital transformation makes companies more profitable, enhances the customer experience and enables businesses to keep up with competitors, it should also always improve the employee experience. If a new technology will not ultimately make the daily responsibilities of employees simpler or more efficient following the appropriate training, then it is not the right technology for the business and will likely not be a success in the long run. A forward-looking approach As the manufacturing industry continues to become more reliant on digital advancements,

Tailor-made furniture production. Tailor-made furniture Tailor-made furniture production. production. Made easy with Made easy with HOMAG. Made easy withHOMAG. HOMAG. With renovations setsetto toramp up in 2021 alongside the newly Withhome home renovations ramp newlyannounced announced‘Super ‘Super With home renovations set to rampupupinin2021 2021 alongside alongside the the newly announced ‘Super Deduction’ tax break, there’s never been a better time for home interior and furniture Deduction’ tax tax break, there’s never home interior interiorand andfurniture furniture Deduction’ break, there’s neverbeen beenaabetter better time time for for home manufacturers to tolook at atexpanding or upgrading their wood processing manufacturers look expanding processingproduction production manufacturers to look at expandingororupgrading upgrading their their wood wood processing production capacities to meet this upward trend. capacities to meet thisthis upward trend. capacities to meet upward trend. Reduce costs and increase production efficiencies... Reduce costs and increase production efficiencies... Reduce costs and increase production efficiencies...

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business leaders must cast aside any negative assumptions surrounding digital transformation, as they may find their organisations unable to thrive without the help of strategically planned and implemented technological innovations. Once the barriers created by the C-Suite’s misguided preconceptions have been removed, business leaders can invest the necessary time and finances into persuading their employees of the benefits through thorough training and support throughout the process. Because of the buzz surrounding digital transformation and its associated technologies, it may seem that manufacturers are much further ahead in their evolution than they

are. In fact, our research has shown that there are many, many businesses in the UK yet to embrace seemingly commonplace technologies, such as ERP and CRM software, that have the power to revolutionise the way they operate. While many may have been able to get away with these traditional approaches until now, the rapid changes brought on by the pandemic have shown that there is not a single business that can rest on its laurels. An open-minded approach to technology will allow manufacturers to be agile enough to cope with the array of challenges presented by the new business landscape. Manufacturers must acquaint themselves with the ways in which

the industry is changing, and the technologies – both existing and emerging – that will enable them to meet modern expectations and demands. Reassuringly, just 7% of business leaders surveyed said that they believe that the traditional way of operating is more effective, suggesting that the vast majority are open to new technologies to some extent. Digital transformation in manufacturing must be viewed on a business-by-business basis, educating and convincing leaders where needed and offering the right guidance and expertise to all employees, from top to bottom, to make it a true success. Business leaders who fail to effectively communicate to employees or do not make enough support available risk alienating certain members of staff, damaging employee engagement and, ultimately, condemning digital transformation efforts to fail. When implemented correctly, digital technologies have the potential to boost productivity, profits and customer satisfaction – but that is impossible without complete employee engagement from all staff members, regardless of their seniority. www.nexergroup.com

Nexer is a leading digital transformation expert, specialising in Microsoft Dynamics. It advises, implements, develops and manages Microsoft Dynamics applications, alongside other technologies, to help clients strengthen their market position, grow revenue, and improve productivity.

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Biesse’s SmartAction concept provides a complete Smart Factory solution to companies of any size Compact, connected, and accessible, Biesse’s SmartAction concept offers companies looking to increase efficiency a straightforward route to transform their operations into a real ‘Smart Factory’. To enable this, machines are connected in real time to deliver optimised production, making manufacturers more efficient, and therefore more competitive – and it is software that leads the way to enable integrated production management. With the complete digitalisation of processes, products can be produced quickly and flexibly, with scope for customisation. Smart Factories are not only in the domain of large-scale production sites – smaller factories

can equally benefit by exploiting all the power and effectiveness of highly integrated solutions, including: • Reduced space with reduced labour • Integrated and optimised production management • Easy management and learning, even for less-experienced operators • Reduced resource consumption • Minimal investment Interconnected machines with B_Cabinet The key to unlocking a Smart Factory is to connect machines, and Biesse enables this via its B_Cabinet software suite, which provides

real-time communication with all machines, from machining centres and panel saws to edgebanding machines, drilling and sanding machines. This allows the software to deliver integrated production management and enable data exchange to send job orders, monitor machines and produce production reports. Compact, financially accessible solutions While the idea of a Smart Factory may seem out of reach to many manufacturers that think it can only be achieved by utilising robots and/ or automated handling systems, as can be seen from the two factory plan layouts, a Smart Factory can operate in limited production

spaces: 150m2 running a cut/edge/drill operation, producing up to 300 machined panels daily utilising a minimal workforce, and a 300m2 production space with a more complex operation producing 500 panels per day. So while every manufacturer’s space and production process may differ, it is B_Cabinet that is central to a Smart Factory being able to run effectively and efficiently, as it helps manufacturers manage production from the 3D design phase through to production flow monitoring, by providing: • Easy management of work phases – cutting, nesting, edgebanding, drilling, assembly, packaging • Dedicated environment for real-time production monitoring, providing order status control • Management and distribution of all data required to run the process, without further manual intervention • Visualisation of production status • Progress of each component • Optimisation of the production process including simulation tools SOPHIA – getting greater value from machines To support the Smart Factory and digitalisation concept, Biesse also has a digital service platform, SOPHIA, where machine and service information is monitored and collated to help customers optimise their assets.

SOPHIA supports increased productivity by providing users with access to machine information, helping to optimise performance and monitor quality. SOPHIA also helps to deliver improved service levels by utilising a SCADA system to collect machine data and by performing test cycles to help anticipate potential future faults and to provide notification of a machine-down status. Therefore, Biesse can take proactive steps to contact customers to help resolve issues faster. Overall, SOPHIA helps to reduce machine stoppages, increase machine availability and consequently output. “Intelligent systems are connecting the world,” comments Robbie O’Neill, UK commercial director. “This allows businesses to adapt more quickly. It is about improving machine availability, performance and quality via physical automation, software and connected machines or facilities. This means a leaner process is required if you want to compete, let alone just protect your business. Biesse can help customers transform their operations and help them to achieve greater efficiency, and therefore derive better value from their machines.” Therefore, the combination of automation and digitalisation can provide real value to customers by helping to improve Overall Equipment Efficiency (OEE), the measure of how well a machine works. 01327 300366 www.biesse.com/uk/wood

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Automation increases efficiency and capacity

A Perry, one of the UK’s largest suppliers and manufacturers of hinges and ironmongery, will now be able to process orders more than four times quicker, after investing seven figures in new automation technology.

The £1.2m investment in picking robots has been implemented to cope with the significant rise in demand seen by A Perry in Q1 2021, and enables the company to vastly reduce day-to-day operational costs and make more efficient use of floorspace, allowing for future expansion of stock volume held on site, plus the variety of products on offer, without the need to relocate. The Cradley Heath-based firm worked with OW Robotics to install 15 fully automated robots and 330 moveable pods in its 5000ft2 warehouse. The installation took just six weeks to install, calibrate and set into action. The Q7 Hikrobots have a weight capacity of 1000kg and provide rapid access to 4000 picking locations containing 15,000 product lines, while

only requiring two packing stations to complete customer orders. Chris Perry, operations director at A Perry, says: “Due to our unique position in the marketplace and significant investments within our supply chain, our stockholding has been considerably better than most of our direct competition, which has resulted in a substantial rise in demand. In the first quarter of 2021 we have seen a +60% increase in orders, and to be able to efficiently facilitate these, this investment in automation has been essential to be able to keep on top of our customers’ expectations. “We’ve been in business for over 95 years but we’re always looking ahead to new innovations, and this could not have been implemented at a more >>

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crucial time. We have invested a significant sum of money, but the automation drives our business forward and will enable us to remain the biggest, most innovative supplier in our field for years to come.” Greg Downey, robotics business consultant at OW Robotics, agrees that A Perry’s robotics implementation will have a significant long-term impact on its order throughput. He says: “Right now, all businesses that operate a warehouse are faced with the difficulties of accessing stock

through the supply chain, rising shipping and freight costs, and also the shortage of stable labour, and these issues all result in slowing picking rates and fulfilment. Online demand for products right across all industries, including this trade, has sky-rocketed in the last 12 months, and that trend is expected to continue. “That’s why A Perry has made this investment in a robotics solution at the right time. Flexible automation is going to be key to businesses who realise the warehouse is central to their

success. Hour to hour, Perry’s implementation will enable it to increase picking rates by up to almost four times – in the long-term, this will mean the business can process significantly more orders to boost sales and revenue. “Demand continues to increase, and Perry has put itself in a great position to be able to scale its warehouse operation to suit peak times and its customers’ needs.” www.perrytrade.co.uk www.owrobotics.co.uk

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www.cadt-solutions.com

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SCM’s Smart&Human Factory for Industry 4.0 The widely admired Smart&Human Factory is SCM’s vision of the factory of the future. It is a system of automated, modular and easily reconfigurable flexible cells, integrated with articulated and collaborative robots and AMR self-guided shuttles that can be programmed according to the production unit plant, capable of moving and working alongside the operator in complete safety. It is a new digital and Smart Factory, but one that is still user-friendly, designed to satisfy the challenges of mass customisation and Industry 4.0 even more effectively and faster, and which goes beyond the traditional automated systems. Already presented at Ligna 2019, after numerous implementations in cutting-edge markets in Europe, the US and China, SCM’s Smart&Human Factory has been enhanced with new additions to further increase productivity and flexibility, reduce waste and optimise the quality of the end product, even on more sensitive materials. >>

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>> A new human automation One of the major impacts emerges from autonomy – especially the transition towards a fully automated lights-out factory. This future factory requires extensive automation and networking of the manufacturing processes. SCM’s Smart&Human Factory is a new model of interaction between man, robot and machine, in open and safe cells. A further improvement is also achieved on the work front, with operators relieved from risky and repetitive activities, so they can focus on tasks with greater added value. Modularity The state-of-the-art SCM cells can be put together by clients as they wish to satisfy the vastly varying processing needs. SCM’s Smart&Human Factory concept can also be expanded to create complete furnishings – bathrooms, kitchens, living areas, bedrooms – within the same production unit by using a series of combinations between the shuttle routes and flexible processing cells. Sustainability Digital production has a particular impact on environmental sustainability. As well as helping to improve a company’s CO2 footprint, it also offers: more efficient energy and water usage; enhanced waste management due to optimised machine handling; and recycling of a large share of production materials. The process aims to optimise as much as possible the cutting, edgebanding, routing and drilling operations of the panels, as if it were a standard production, in order to reduce rejects, leftovers and changes to the machine setup when changing orders, and it recomposes the orders at the end of the process, moving the customisation to this phase. Digitalisation In the Smart&Human Factory conceived by

SCM, the whole system is optimised by the Digital Integrated Woodworking Process. Software and digital services can assist the customer at each stage of the process in creating the piece of furniture – from the planning and preparation of the data to machine production, production monitoring, maintenance and after-sales service. Planning – in response to production planning needs, SCM offers a new MES solution integrated into the SCM machines to assist customers with programming and managing the production flow. Thanks to the MES, any item of the production orders is tracked and the material flow managed in order to keep the output efficiency at the best. The mix of many different processing technologies usually escalates the risk of bottle necks. That is why having a supervising software guarantees the proper efficiency and smooth flow of the components passing through the production process. Production – a better interaction with the machine. The new HMI multi-touch Maestro active demonstrates how it is possible to have

control and an even simpler, better interaction with the machine, at the production stage. Monitoring – all of SCM automation systems (ie lines and cells) always come equipped with different systems to monitor the efficiency and the performance of the production line. Maestro Active Watch supervision software, integrated with SCM MES or another company’s IT systems, allows the production process to be managed and controlled, for example, by monitoring in real-time the state of individual machines and the entire line, optimising production performances. Maestro Active Watch also creates a two-way interconnection with the MES, allowing part programs to be loaded remotely from office to factory and returning production reports that can be analysed in the office. Finally, the machine can be monitored in real-time every time and everywhere thanks to ‘Maestro connect’ production monitoring digital services. Maintenance and after-sales – the IoT Maestro Connect platform collects and analyses the data about the actual use of the machines, improves the availability and

reduces the downtime, offering a full range of digital services – related, for example, to the maintenance of the machine, the service support, or the performance analysis. SCM smart technologies for Industry 4.0 SCM is by its customers’ side to support them in the digital transformation process. The term Industry 4.0 describes a new industrial revolution driven by the digital automation of factories and by the Industrial Internet of Things (IIOT). It has become a byword for industrial digitalisation, manifesting itself in company strategic agendas and research projects, and driving the use of buzzwords such as digital factories, Big Data, artificial intelligence (AI) and collaborative robots (cobots). Five key macro-economic trends have been identified and assessed – summarised in the acronym IDEAS – along with their impact on these value chains, players and markets. Mastering and using those trends to their advantage will be the key for many companies:

These smart factories are equipped with advanced sensors, embedded software and robotics that collect and analyse data and allow for better decisionmaking. Even higher value is created when data from production operations is combined with operational data from ERP, supply chain, customer service and other enterprise systems to create whole new levels of visibility and insight from previously siloed information. Developing smart factories provides an incredible opportunity for manufacturers entering the fourth industrial revolution, says

SCM. Analysing the large amounts of data collected from sensors on the factory floor ensures real-time visibility of manufacturing assets, and can provide tools for performing predictive maintenance in order to minimise equipment downtime. SCM technologies for Industry 4.0 lead to increased automation, predictive maintenance, self-optimisation of process improvements and, above all, a level of efficiencies and responsiveness to customers not previously possible. www.scmgroup.com

I – Individualised: Batch to size one D – Digital: Smart connected factory E – Enabling technologies: Advanced HW and SW tech A – Autonomous: Lights-off operation S – Shared B2B assets: New service model

Manufacturers are integrating enabling technologies, including Industrial Internet of Things, cloud computing and analytics, and AI and machine learning into their production facilities and throughout their operations.

Are all apples the same

If you are investing in panel processing equipment make sure you compare apples with apples

01235 557 600 | www.holzher.co.uk

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Norbord automates labelling of 100s of pallets per day with ZetesAtlas Norbord, one of the world’s largest manufacturers of wood-based panels, produces more than 1200m of OSB panels per day at its Genk location. Every day the logistics employees apply 1400 labels to pallets in order to manage the panels and stock. This process was recently automated at Norbord’s Belgian location with a Zetes industrial labelling machine and ZetesAtlas identification software. After the manufacturing process, the Norbord panels are placed on pallets and wrapped in protective film. Information about the pallets, the OSB panels and their location in the warehouse is stored in the ERP system. It also prints the labels that are applied to the respective pallets and scanned. Until recently, these labels were printed in advance, so the forklift operators had to leave their cab each time to label and scan a pallet. In order to automate the process, Norbord opted for ZetesAtlas, an integrated solution for identification and serialisation. After pallet wrapping, the machine applies the label – always in the same place – and automatically scans the barcode with the stock location and batch number. Then ZetesAtlas ensures that the pallet is shown correctly in Norbord’s warehouse management software. The forklift operator enters the stock locations only once at the start of their shift. Once the pallet has been scanned, the operator takes it to the designated place in the warehouse with an area of approximately 40,000m2.

Automation boosts safety and reduces errors With the help of the automated solution, the forklift operators no longer have to leave their cabs to apply and scan the labels. This also dramatically improves safety, since there is always a risk of falling every time a forklift operator exits or enters the cab. “The difference since our project with Zetes is

enormous,” says Steven Brouillard, department manager finishing end operations at Norbord. “We save time, and we are more efficient with fewer scan errors. We were just about to start up a second production line. Thanks to ZetesAtlas, we are now working with an additional line but with the same team. The new solution came at the right time.” A new way of working with ZetesAtlas “It’s not easy to link industrial machines to ERP or WMS software,” says Stefan Nysen, systems developer at Norbord. “For us this worked out very well, with smooth co-operation between our engineering and IT teams on the one hand and Zetes on the other hand. Instead of running on its own in a remote corner of the warehouse, our machine is fully integrated into our operations, thanks to the ZetesAtlas identification software.” Fast delivery Steven Brouillard concludes: “Zetes impressed us with their very professional approach. We started in March 2019 with the first contact, and six months later our two machines were already running at full speed. We also appreciate that we can call Zetes whenever we want to. Looking back, we could ask ourselves why we waited so long.” www.zetes.com

Smart thinking from Holz-Her Looking to invest in a smart and flexible edgebanding solution that offers some impressive Industry 4.0 credentials? Holz-Her’s patent-protected Glu Jet system has you (and your edging) covered. Benefiting from a four-minute changeover between EVA or PUR, three minute heat-up time, two glue systems, thin film technology for invisible joints and a three-year warranty as standard, the Glu Jet comes equipped with a comprehensive management system that monitors a full range of settings including heat, pressure and application timings integrated within the machines process control. With a wealth of automated features, the

Glu Jet system offers a clever glue quantity monitoring system – which allows you to know exactly how many jobs can be completed when the necessary criteria has been set – an optimised nozzle that automatically adapts to the thickness of a panel and compensates for any tolerances and automatic cleaning at the push of a button, that work together to create a consistently high-quality glue application, every time. If connected manufacturing is where your processes lie, Holz-Her’s new IOT viaCockpit digitalisation package is a game-changer. Teamed with the Glu jet system on all Auriga, Sprint and Lumina edgebander models, the

viaCockpit software suite, designed by Weinig Group, remotely monitors the productivity of the machine. Constantly monitoring running hours, this Integrated 4.0 smart factory technology allows you to oversee preventative maintenance or spot irregularities in real-time on any mobile device. Keen to find out more about Holz-Her’s patent-protected Glu Jet system? To book your demonstration or to talk to a Holz-Her edgebanding expert, call 01235 557600. www.holzher.co.uk

SMART Furniture & Joinery Production

With over 50,000 units sold worldwide, we take a closer look at why Holz-Her’s patent-protected Glu Jet system is such a popular solution for making ultra-thin glue joints achievable when using both PUR and EVA.

Holz-Her’s Glu Jet system

LTRONIC laser edging unit Holz-Her’s change-over Ltronic laser edging unit has been developed especially for the LUMINA series and processes all edging on the market with functional layers. Not only does the unit achieve perfectly invisible joints, it requires no heat-up time, operates silently and requires no cleaning work.

Four minute change-over with EVA or PUR

Cartridges and granules

100% adhesive force at all times

The patented Glu Jet system takes just four minutes to change from EVA to PUR and four minutes to clean down when using PUR thanks to its automatic cleaning system. Its hybrid technology also allows you to change from coloured to neutral glue quickly, allowing you to colour-match your EVA or minimise the glue line thickness when using PUR.

Glue cartridges, glue granules or both. There’s no need to choose between the two with the Glu Jet, and changeover is achievable in just two minutes.

The Glu Jet only ever melts the glue that is needed, ensuring that the glue always maintains its full adhesive force without losing strength from repeated heat-up. This process also saves energy, too.

Glu Jet PUR 2K The XL Glu Jet station allows users to process 2kg glue cartridges, which are significantly less expensive than conventional PUR granules. A worthy investment for those using 2kg of PUR glue per day.

Paul Nightingale NATIONAL SALES MANAGER – HOLZ-HER UK

“There is a reason why our existing Holz-Her customers have repeatedly proven their loyalty to our brand and placed their confidence in Holz-Her. Once they have moved away from using glue pots, they don’t want to move back. The advantages to using PUR are clear – it offers a zero glueline, allowing you to enhance the overall aesthetics, whilst increasing performance – and thanks to decades of development, Holz-Her’s Glu Jet system delivers edgebanding in minutes.” 01235 557600 www.holzher.co.uk

Precise application The Glu Jet features an optimised nozzle that automatically adapts to the thickness of a panel and compensates for any tolerances. This guarantees strong, clean joints between the panel and edging, even on panels with highly varying thicknesses – and it saves spoiled panels. There’s also a clever glue quantity monitor, so you’ll always know how much work can be completed.

Automatic cleaning operation Say goodbye to the complicated, labourintensive cleaning of glue pots and glue rollers and hello to automatic cleaning at the push of a button. It really is that quick and easy. Even when changing from EVA to PUR, the system takes just four minutes to complete its cleaning cycle, compared to other processes that can take 12-14 hours.

Three minute heat-up time

Three-year warranty

From zero to operating temperature in just three minutes and back to zero just as quickly. A traditional edgbander can take over 15 minutes.

Have extra peace of mind knowing your complete Glu Jet system is covered by a three-year warranty. That’s the HolzHer quality guarantee.

Energy saving The Glu Jet only uses 2.1kW – three times less than a standard pre-melt machine – offering a potential saving of up to £2000 per year on your energy bill.

Zero joints on all edges with PUR The new Glu Jet thin film technology ensures glue penetrates deeply into the panel, providing a high-strength and invisible joint when using PUR. From state-of-the-art, high-gloss edging right up to thick cross sections in solid wood, the Glu Jet makes flexible manufacturing a reality. Unlike laser applications, the system delivers zero glue line to solid wood, melamine, HPL, real wood coil and veneer.

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CAD+T – combating a changing market

While there remains a level of uncertainty surrounding Covid-19 and its long-term effect on the economy, one thing has become clear – now is the time for the furniture industry to embrace technology and digitalisation and reap the benefits it has to offer. “It’s no longer a question of if companies need to integrate intelligent technology into their business, it’s when,” begins Martina Schwarz, international sales & marketing manager at CAD+T Consulting. “People have seen firsthand how important it is for businesses to be

prepared and how technology has a huge part to play in their ongoing success. We’ve seen a huge surge of interest from companies keen to invest in cloud-based software, as they begin to restructure their processes and create a practical online structure that could combat the effects of future outbreaks.” Martina continues: “The industry’s mentality has changed. Site visits are becoming a thing of the past for many customers and remote working is here to stay. Our cloud-based software can be accessed anywhere in the

Planning module professional

world using something as simple as a mobile device. You still get the same functionality you’d expect when using a powerful desktop computer, but it’s considerably more flexible, a fraction of the price you’d pay for the latest CAD hardware, and it’s continually updated.” It is also extremely flexible, and is designed around the client. Martina says: “In the last 12 months, consumers’ buying habits have changed, which means many of our customers have had to diversify. With our bespoke software offering, it doesn’t matter if you change your product range or target audience multiple times. “As long as you can identify the product in your design, our software works exactly the same way. Customers have the ability to change their manufacturing methods in a matter of days to stay ahead.” © Act-3D-BV

Below: Cabinet Configurator

Training has also been adapted to suit the current climate, with CAD+T moving away from direct training to focus on its online offering. Sessions can be fully customised and include up to five people, allowing a small team to take part in the same training programme remotely. Martina adds: “We pride ourselves on being able to create customised software solutions – it’s what we do and it’s what we’re good at. During this time of uncertainty, the power of digitalisation has come into its own, and our experience in this field has allowed us to help our customers overcome a wide range of challenges and introduce even more businesses to our innovative software solutions. “We’re proud to represent the furniture design and manufacturing industry, and pleased to see the market bouncing back so quickly.” www.cadt-solutions.com

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Larger premises aids automation company expansion Gripple Automation has expanded rapidly in recent years to become a multi-millionpound business – which is why it has moved into new premises in Sheffield. The new premises is more than double the size of its original production site, at 13,140m². It provides a cleaner, more modern environment, and now boasts dedicated proof-of-principle area, more machine building areas and a larger inhouse machining department. New services and new people These new services, combined with more space, are allowing the manufacturing automation specialist to streamline its standard operating procedures while taking full advantage of new opportunities provided by the expanded factory. The facility houses new equipment as well as new people, with four new starters last year in design, production and inhouse manufacturing, as well as a new apprentice. Meanwhile, the company says that business is booming, with a number of machines having been recently delivered which are making space for the next batch of new machine builds. www.grippleautomation.com

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Pytha 3D-CAD Version 25 – flexibility meets perfection

From concept to completion, Pytha 3D CAD is one of the leading 3D CAD systems for the woodworking industry, furniture design, commercial joinery, highend kitchen, exhibition planning and interior design sectors.

With its powerful Version 25, German software developer Pytha Lab sets high standards in the world of CAD. A particular highlight in V25 is the new, seamlessly integrated render engine, which allows high-end rendering directly in

the Pytha modeller. Within seconds, users can now see a photorealistic image without having to switch programs first. Afterwards, it is easy to continue working within the scene that has been created. Pytha thus enables every user to

achieve almost perfect results with little effort. No expert is needed for this – lighting a scene is really easy and straightforward. Intelligent brightness settings create impressive image calculations, whether day or night. An HDR-panorama image generates a natural and atmospheric light. Luminaires are easily and precisely matched to light values in lumens (brightness) and Kelvin (colour temperature). Frequently used lamp settings can, of course, be stored in a separate library and retrieved at any time. The render engine now also features real indirect light, which gives the user a realistic colour impression. Improved materials give the scene a real vibrancy. Pytha’s developers have also improved the speed of the calculation of a scene. An intelligent noise filter called ‘denoising’ generates a finished image of the highest quality within seconds. This allows any user to render projects in photorealistic quality and create convincing presentations. These, and many other new features, are available with Pytha Version 25. www.pytha.com

Not all apples are the same

GLU JET The key to a flexible edgebander Invisible joints with thin film technology Ready to run in 3 minutes EVA or PUR? 4 minutes changeover Cartridges or granules Simple colour change Laser equivalent at a fraction of the price

Uniquely HOLZ-HER! 01235 557 600 | www.holzher.co.uk

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Elfin Collaborative Robot – providing flexible and reliable support for the automation industry As industry today strives for more efficiency, increased output and reduced costs, Motion Control Products (MCP) has introduced the next generation of Elfin series six-axis collaborative robots to support the automation procedures associated with repetitive tasks. The Elfin robot arm system integrates the motors, harmonic gearboxes, brakes, feedback devices/sensors, drives and cables into a compact structure. This achieves high precision and flexible automation control in six-axis of rotation, each with a full 360˚ of movement. MCP’s cobots features high-accuracy positioning up to ±0.05mm, with a speed of up to 90° per second. It has a default force setting to ensure that it will automatically stop when encountering an unexpected obstacle. Elfin series collaborative robots weigh from 17-40kg, with a standard working load capacity of 3kg (Model E3), 5kg (Model E5)

and 10kg (Model E10), which ensures that there is a product offering for a wide range of applications. With EtherCAT bus communication and highly integrated modular design, MCP’s cobot is compact, is easy to programme via a control panel for multiple Elfin robots, and offers the user a fast set-up solution and real-time control under the most open ROS platform. Motion Control Products are available to support the user through correct specification, commissioning and training if necessary, thus ensuring that the collaboration in the workplace is optimised and safe. MCP’s technical staff can also provide customers with an accurate payback period, which is often surprisingly fast. This can then relieve existing manual staff from often dull, repetitive tasks to enable them to support the company in more challenging roles.

The three robot arms are a desktop- or surface-mounted system, and have a working range up to a maximum of 1000mm and a working life of 35,000 hours. Typical examples of where one can consider the use of collaborative robots would include CNC pick and place, screw driving, painting, polishing, welding, gluing, palletising/packing and assembly and more. The Elfin robot series support installation at any angle. Redeployment requires only a very short period of time. It is very suitable for small batches, customised, short-cycle production, and is the best choice for automation. The product conforms to ISO/TS15066 and can be safely used alongside a company’s workforce with no safety guarding once a risk assessment has been completed. 01202 599922 www.motioncontrolproducts.com

Elfin Module Series

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Laying the basis for right-sized automation By Nigel Hyland Commercial manager, Comau UK nigel.hyland@comau.com

Founded as the Consorzio Macchine Utensili in 1973, by the mid-80s Comau had already developed its first robotised system. The company soon began its global expansion, opening Comau UK in the early 90s. Today, backed by a full range of competencies, from concept design and engineering to full-line integration, Comau UK provides flexible, tailored and valueadded solutions to customers within and beyond the UK, and across various manufacturing and materials management sectors. In addition to a full range of assembly systems, machine tooling and industrial robotics, its comprehensive portfolio includes Industry 4.0-enabled technologies and interconnected digital solutions. Comau UK also offers the added

benefit of leveraging the resources of Comau’s global organisation when needed, while enjoying an extensive and mature supply chain in the UK. When it comes to automation, Comau UK specialises in helping organisations of all sizes experience higher quality, increased productivity, faster time-to-market and lower overall costs. Yet automation is much more than huge projects, highspeed robots and big numbers. It can be as simple as a solution to lift wood panels above a certain weight. Comau’s intimate knowledge of process dynamics and workflow optimisation puts the company in a unique position to help the furniture and joinery industry leverage the benefits of what the company calls ‘right-sized automation’. In some

cases, this involves allowing industrial robots to work safely and securely alongside craftsmen, or using advanced technology such as the MATEXT wearable exoskeleton to accommodate non-automated lifting, moving and positioning of heavy and cumbersome materials. Automation can also mean letting sensors track, trace and predict, or allowing technology to perform mundane work such that human operators can focus their talents on value-added activities. Finally, automation helps ensure the same quality standard for all finished products, with waste and rework reduced to a minimum. When approached in a holistic manner, automation can be designed in a simple and incremental way – automate a single process, for example, or deploy flexible AGV-based (autonomous guided vehicle) logistics to move stock, materials and products. The first consideration for any company exploring the benefits of automation is finding a supplier which is also a good consultant – one that can help ascertain the appropriate level of automation (which in some cases could be zero), and analyse the pinch points to create

Comau’s new Racer-5 COBOT has been designed to allow human operators to focus on valueadded operations in tandem or alongside the cobot while the robot performs repetitive tasks

a solution that can positively impact the customer’s bottom line. Take de-palletising and palletising operations, for example. A consultancy-backed approach entails conducting a careful analysis of the process, identifying tailored automation opportunities and working with the customer to determine the quantifiable benefits. Looking specifically at the needs of furniture and joinery, Comau UK can help identify opportunities to automate existing processes such as machine tending. In other cases, it may make more sense to automate a specific element of a process, such as adhesive application or stud/fastener insertion – or a machining operation such as routing, drilling or cutting. Similarly, for assembly operations, Comau UK can help manufactures identify where routine and repetitive operations for the assembly of standard products could be automated utilising robotic arms or dedicated bespoke systems. Examples include pick-andplace operations, the mating of components or the use of collaborative robots (cobots) to assist with manual processes. Intralogistics solutions is another interesting opportunity for the furniture and joinery industry, as mentioned earlier. Take the AGILE1500 fullyautomated guided vehicle, for example. It can carry up to 1500kg and is flexible enough to be deployed across a wide range of manufacturing and non-manufacturing scenarios. As such, the AGV can help optimise logistics flows and support customised and efficient production while safeguarding productivity and profitability. Finally, the benefits of digitalisation should not be ignored, as sensorisation facilitates machine/control integration. It therefore enables companies to gather manufacturing data from key process points, which aids the creation of management information and KPIs. Through sensorisation, Comau UK can grant visibility and

tracking of inventory, materials and unfinished products, thus allowing manufacturers to better control production throughput and output. In addition to enabling production planning and material planning, digitalisation lets the system communicate with different parts of the operations in a true Industry 4.0 environment. Companies can thus enjoy smart manufacturing capabilities, such as automated logistics that deliver the right materials at the right time based on the actual cycle time of the manufacturing line. Applying sensors and data-gathering capabilities in key process areas enables condition-based monitoring and maintenance operations, so minimising machine failures, downtime, interventions and costs. Digitalisation also allows manufacturers to track and trace parts and products throughout the entire workflow. Yet while the technology itself is an important enabler, maximising its benefits necessitates a clear understanding of what can and could be achieved and the necessary deliverables to reach the goals. Here is where Comau UK’s consultant-based methodology plays a key role, in forming the foundation of a solid and lasting relationship with its customers. By approaching each project as a partner rather than as a supplier of products and services, Comau works in close synergy with each customer to reach common objectives. This is especially helpful when working with companies that are new to automation. In most cases, the adoption of automation for traditionally manual crafts such as furniture and joinery requires Comau’s experts to guide the process in order to mitigate any fears the customer may have. This also allows Comau to make sure the potential benefits are identified and understood, in order to create appropriate >> expectations.

36 SMART Furniture & Joinery Production >>

The advantages of Comau’s approach are numerous, and encompass each phase of the project, from its start throughout its development – beginning with the preliminary discussions, the design execution and installation of the solution at the customer’s workshop, through to its operational management over time. More importantly, Comau’s consultative approach allows it to fully understand the customer’s pain points, and the challenges and objectives within their production processes. Comau’s team carefully studies the existing set-up to see where inefficiencies lie, where there are bottlenecks in production, where output and productivity need to rise, where costs need to be reduced, and where quality and consistency need to improve. These are the essential elements that enable Comau to maximise results and make manufacturing more productive and more flexible than ever before. To use a concrete example, integrating collaborative robotics within a highly manual manufacturing approach can be an ideal way to add automation without losing the human aspect of the craft. It can thus become a starting point for businesses looking to increase quality and productivity in a cost-effective manner, even in small spaces and within applications such as handling and assembly. This opens the possibility for true autonomy in the robot’s ability to co-operate with humans in complete safety, side-by-side, with each

executing their respective tasks to the best of their natural abilities. Such automation can be used for heavy, boring, repetitive and dangerous tasks, or tasks that necessitate extreme speed. In tandem, the human operator focuses on tasks that require intelligence, care and dexterity. Indeed, Comau’s new Racer-5 COBOT was designed to allow human-operators to focus on value-added operations in tandem or alongside the cobot while the robot performs repetitive tasks. Yet the exciting and unique aspect is that it can automatically and instantly switch from its industrial mode to collaborative mode when a human operator is nearby.

Thanks to this dual nature, Racer-5 COBOT can work at full speed when human operators are not in the vicinity and at collaborative speed when they are – ensuring high productivity and reduced cycle times. In addition, the compact footprint and advanced safety features of the six-axis articulated robot can help ensure optimal industrial efficiency while granting the added benefit of safe, barrier-free operations. Another interesting development for the industry is found within artificial intelligence (AI) and advanced vision systems. These key technologies are offering increased control, autonomy and opportunities to undertake tasks once thought impossible to give to a machine. As both AI and vision technologies can be easily integrated with other systems, machine tools and equipment, they facilitate better interconnection and shared data. They also create a context in which decisions can be taken independently of human intervention, thus maintaining fluidity on the shop floor. In closing, the powerful technological developments taking place in robotics, digital intelligence, machine inspection and machine recognition will result in radical paradigm changes in multiple sectors. The degree to which this will happen is difficult to define, yet applying the correct level of automation, at an acceptable ROI, is something all companies should be looking to address. www.comau.com

The MATE-XT wearable exoskeleton accommodates non-automated lifting, moving and positioning of heavy and cumbersome materials

FIT FOR WORKERS WHERE DOES IT WORK? WHERE YOU DO.

MATE-XT is the exoskeleton that brings the qualities of MATE to an eXTreme level. The new MATE-XT is the latest version of the Comau exoskeleton that has been vastly improved, taking its benefits to the next level and adding important new features. Resistant to water, dust, UV rays and high temperatures, it is ideal for applications in difficult environments. MATE-XT is easy to wear, easy to adjust and easy to use, ensuring the worker: • • • •

Muscle fatigue reduction Improved posture and comfort Risk reduction from biomechanical overload certified with EAWS methodology Better quality of work

MATE-XT works when, where and how you do. Discover more on comau.com/mate

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Mirka introduces new robotic sanders and polishers to meet demand for automation

Industry automation is a growing trend in many sectors, from wood to automotive and transportation, with customers requiring a complete package for automated manufacturing processes. To meet this demand, Mirka is introducing a range of new robotic sanding solutions including the Mirka AIOS sanding heads and the Mirka AIROP polishing head, which will join the Mirka AIROS, the first smart electric sander designed for robotic sanding applications. The products are engineered for what Mirka describes as ‘roboticised finessing’, ensuring consistent quality while saving time. For industrial processes such as furniture,

doors and windows manufacturing where a rectangular sanding solution is required, the AIOS 353CV, with its 81 x 133mm pad, is suitable for surfaces and corners alike. It can be used to drive up productivity and finishing quality with robotic precision. For sanding, the Mirka AIOS 130NV is aimed at spot repair work in an automated process such as in car and transport manufacturing. The Mirka AIROS 150NV is the smallest AIROS sanding head, ideal for more confined spaces, detail work and sanding of small areas where deflashing or deburring is required. The Mirka AIROP 312NV is a random orbital polisher with an advanced electric polishing head for robot

usage. Featuring a 77mm pad, it provides a robotic alternative to Mirka’s cordless polishers, and is compatible with Mirka’s polishing pads and compounds. Ian Deery, business sector manager transport and industry for Mirka UK, says: “More businesses are investing in automated manufacturing processes, and tools are key to delivering effective results. The addition of the AIOS sanding heads and AIROP polishing head alongside the AIROS ensures we can provide our customers with a complete solution that is suitable for use across multiple applications and sectors.” www.mirka.com

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ABB launches next-generation cobots to unlock automation for new sectors and first-time users ABB is expanding its collaborative robot (cobot) portfolio with the new GoFa and SWIFTI cobot families, offering higher payloads and speeds, to complement YuMi and Single Arm YuMi in ABB’s cobot line-up. These stronger, faster and more capable cobots will accelerate the company’s expansion in high-growth segments including electronics, healthcare, consumer goods, logistics and food and beverage, amongst others, meeting the growing demand for automation across multiple industries. GoFa and SWIFTI are intuitively designed so customers need not rely on in-house programming specialists. This will unlock industries that have low levels of automation, with customers able to operate their cobot within minutes of installation, straight out of the box, with no specialised training. “Our new cobot portfolio is the most diverse

on the market, offering the potential to transform workplaces and help our customers achieve new levels of operational performance and growth”, says Sami Atiya, president of ABB’s Robotics & Discrete Automation Business Area. “They are easy to use and configure and backed by our global network of on-call, online service experts to ensure that businesses of all sizes and new sectors of the economy, far beyond manufacturing, can embrace robots for the first time.” ABB’s cobot portfolio expansion is engineered to help existing and new robot users accelerate automation amid four key mega-trends including individualised consumers, labour shortages, digitalisation and uncertainty that are transforming business and driving automation into new sectors of the economy. The expansion follows the business area’s focus on high-growth segments through

ABB boosts YuMi collaborative robot portfolio with GoFa and SWIFT cobot families

portfolio innovation, helping to drive profitable growth. Automation driving the future of manufacturing In a global survey – ABB Industry Survey January 2021, conducted by 3Gem Global Market Research & Insights – of 1650 large and small businesses in Europe, the US and China, 84% of businesses said they will introduce or increase the use of robotics and automation in the next decade, while 85% said the pandemic had been ‘game changing’ for their business and industry, with Covid-19 a catalyst for accelerating investment in automation. Nearly half of businesses (43%) said they were looking to robotics to help them improve workplace health and safety, 51% said robotics could enhance social distancing, and more than one-third (36%) were considering using robotic

automation to improve the quality of work for their employees. More immediately, 78% of company CEOs and MDs said recruiting and retaining staff for repetitive and ergonomically challenging jobs is a challenge. Cobots are designed to operate in the presence of workers without the need for physical safety measures such as fences, and to be very easy to use and install. In 2019, more than 22,000 new collaborative robots were deployed globally – up +19% compared to the previous year. The demand for collaborative robots is estimated to grow at a CAGR of +17% between 2020 and 2025, while the value of global cobot sales is expected to increase from an estimated $0.7b in 2019 to $1.4b by 2025. The global market for all industrial robots is projected to grow from $45b in 2020 to $58b by 2023 (CAGR of +9%). GoFa and SWIFTI are engineered to help businesses automate processes to assist workers with tasks including material handling, machine tending, component assembly and packaging in manufacturing, medical laboratories, logistics hubs and warehouses,

Eight out of 10 workplaces say they will increase use of robots in the next decade – pandemic cited as catalyst for accelerating investment in automation workshops, and small production facilities. “With this expansion, we are making cobots easier to use and deploy, with real-time support to help speed their adoption in businesses that may have not considered their use previously,” says Sami. “Our experience is that the best-performing operations harness people’s skills, alongside the potential of new technologies.” Users comfortable with operating a tablet or smartphone will be able to program and reprogram the new cobots with ease, using ABB’s

fast set-up tools. Customers will also benefit from ABB’s global industry and application expertise, which has been developed from installing more than 500,000 robot solutions since 1974, and supported by ABB’s network of over 1000 global partners. The new GoFa and SWIFTI cobot families build on the success of ABB’s YuMi family, which has been helping businesses safely automate key tasks since YuMi, the world’s first truly collaborative robot, was launched in 2015. Today, ABB’s YuMi cobots are working alongside people in factories, workshops and laboratories all over the world, performing tasks from screwdriving and assembling electronics and electrical components, to making valves and USB sticks, and testing Covid-19 samples in laboratories. Every ABB cobot installation includes a startup package that provides ABB Ability condition monitoring and diagnostics, as well as a support hotline free for the first six months to access ABB’s expert technical assistance, which is offering support across all industry segments. https://new.abb.com/products/robotics/ collaborative-robots

42 SMART Furniture & Joinery Production

Rockwell Automation and Comau partner to simplify robot integration for manufacturers Rockwell Automation Inc, the world’s largest company dedicated to industrial automation and digital transformation, and Comau, a global leader in industrial automation and robot manufacturer, have announced that they are joining forces to give businesses worldwide vital tools to maximise manufacturing efficiencies through unified robot control solutions. “Industrial companies are looking for efficient ways to integrate robotics into their operations for process optimisation and agility,” says Rockwell Automation chairman and CEO, Blake Moret. “Rockwell Automation’s collaboration with Comau will simplify programming and lifecycle management, accelerating time to value for our customers.” Blake says this expansion of robotic applications is rooted in Rockwell’s broader strategy to help industrial companies save time and improve performance with unified robot control, ultimately providing long-term value for their business. This collaborative development and selling model offers the unified robot control product to both companies’ customers. “Comau’s robotics and industrial automation expertise, as well as its reputation for high performance, reliability, and quality, combined with Rockwell Automation’s global capabilities and experience in automated material handling, food and beverage, household and personal care, and life sciences, give customers the incremental value of an integrated robot solution,” says Comau CEO Paolo Carmassi. “Comau is eager to work with such an important partner that has a market-leading global footprint in all industries.” Engineers will now be able to program their entire machine in one environment, including Comau

robot arms directly controlled through Rockwell Automation’s Logix-based controllers. Rockwell Automation’s Studio 5000 automation system design software provides relief from the time-consuming and often difficult task of trying to co-ordinate traditionally separate machine control and robot systems to work together using two different software tools. Machine builders, system integrators and others will gain development and deployment efficiencies through the use of digital engineering tools like Rockwell’s Emulate 3D digital twin software, which creates digital models of production lines, autogenerates machine control code, and has built in capabilities for Comau robots. The combined Rockwell and Comau solutions will also offer benefits beyond enhanced integration. For example, endusers can use analytics and digital twin tools to gain deeper insights into machine performance and potential production optimisation. They can also use safety and security solutions to reduce business risks. Operators on the manufacturing floor who use Rockwell’s FactoryTalk software suite will benefit from being able to see both line and robot control systems on a single interface. In-plant and remote technicians will only need to learn and maintain one architecture to monitor both systems. They can also leverage Rockwell’s augmented reality (AR) tools to improve lifecycle and service cycle maintenance. Automazioni Industriali Capitanio, a recognised system integrator, designs, manufactures, and commissions automation systems for the metals industry and is an early adopter of the joint solution. Marco Capitanio, MD of AIC, says

The new collaboration offers industrial customers easier, smarter, and more productive ways to design, deploy, and manage robot applications

the Rockwell-Comau collaboration allows the company to offer a seamless robot solution for customers, which he sees as a key advantage for a machine builder. “We value the simple and flexible programming environment, complete access to robot supervision and diagnostic parameters, and the ability to leverage existing automation panels and standard control devices,” says Marco. Rockwell products and technology that will be key to robotics integration include the following: • Allen-Bradley ControlLogix control systems • Kinetix 5700 servo drive platform

• Studio 5000 automation system design software • FactoryTalk View human machine interface (HMI) software • FactoryTalk InnovationSuite, powered by PTC digital transformation software suite • Emulate3D digital twin software • PTC Vuforia AR tools for remote collaboration and information capture

Comau’s comprehensive robot range meets the needs of a wide variety of industries, from automotive to logistics, food and beverage, and packaging, just to name a few. It includes more than 40 different industrial robotic arms, with load capacities from 3-650kg. www.rockwellautomation.com www.comau.com

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Smart Furniture Production 2021

Articles inside

ABB unveils its next-generation cobots, which it says are ideal for first-time users

Mirka shows us its latest robotic sanders and polishers for use in automation

Rockwell Automation Inc and Comau are joining forces to give businesses worldwide vital tools to maximise manufacturing efficiencies through unified robot control solutions

As industry today strives for more efficiency, increased output and reduced costs, Motion Control Products has introduced the next generation of Elfin series six-axis collaborative robots to support automation

See the quality of the Pytha 3D CAD system for the woodworking industry, furniture and joinery design, high-end kitchen design and more

We take a look at Gripple Automation, which has expanded rapidly in recent years and has now taken on new staff and a larger premises in Sheffield

Moving beyond traditional automated systems, SCM’s impressive digital and smart factory is still user-friendly, designed to satisfy the challenges of mass customisation and Industry 4.0 even more effectively

Labelling tech experts, Zetes and ZetesAtlas, have enabled Norbord’s Genk, Belgium operation to keep on top its logistics – a smart solution indeed, bearing in mind the factory’s considerable output, which requires some 1400 labels to be applied

Biesse’s SmartAction concept provides a complete Smart Factory solution to companies of any size

Nexer’s Colin Crow advises how important top-to-bottom support is when embarking on a digital transformation

Jake Athey tells us how Widen Collective stepped to answer Suncast Corporation’s need of a smart solution for its image library

Made Smarter demonstrates how it is helping furniture and joinery businesses to engage and adopt high-tech, smarter technologies

Major hinges and ironmongery firm, A Perry, can now process orders much quicker after considerable investment in automation technology