Manufacturing Update - June 2022

MANUFACTURING PDATE www.manufacturing-update.co.uk

June 2022

HEATWAVE

- Images Hot enough to Cut the Mustard!

Photography for Industry See inside pages 10 & 11

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MANUFACTURING UPDATE At the forefront of digital marketing, Manufactuing Update strives to bring its readers the latest in industrial manufacturing, in a format that provides the best usability and ease of use for it’s readers. www.manufacturing-update.co.uk

June 2022

Publication Director

Editorial Assistant

Publishing House

Kane Weller 01843 580 460 Kane@engineering-update.co.uk

Laura Sharpe 01843 448 443 laura@engineering-update.co.uk

Jet Digital Media Ltd, Suite 1 & 2 Spratling Court Offices, Spratling Street, Manston, Kent CT12 5AN

Sales Director Tim Johnston 01843 448 443 Vision Engineering - Half Page advert tim@engineering-update.co.uk

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ENGINEERING PDATE

May 2022

Three days of innovation, partnerships and excellence: Subcon is back for 2022!

Subcon returns on the 7- 9 June 2022 to the NEC, Birmingham. Now in its 45th year, it remains the UK’s premier event dedicated to subcontract manufacturing buyers, enabling them to source suppliers, benchmark capabilities, and form new manufacturing partnerships.

At Subcon, find everything from product design, prototyping and development, contract and subcontract products and services through to machine tools, systems and equipment.

This June, Subcon will once again be collocated with The Engineer Expo and Manufacturing Management Show, bringing together even more of the best suppliers, latest innovations and practical advice.

World-class solution providers: The exhibition Across the three show days the exhibition will deliver the contacts, connections and content that engineering and manufacturing businesses in the UK need to succeed. Visitors will be able to harness new innovations from over 200 world class suppliers to help increase capacity, optimise productivity and improve flexibility, whilst also driving down costs to stay competitive in a global market.

Subcon exhibitors span a massive range of manufacturing and engineering businesses, including assembly work, CNC machining, metal fabrication, 3D printing and many more. As this diversity of exhibitors shows, there will be huge opportunities to forge strategic partnerships and improve existing processes.

Exhibitors include: Lapping Services The UK’s largest bespoke lapping and polishing sub-contractor, Lapping Services specialise in double sided lapping, high volume to 1 off’s AS9100 Rev D and they are RR nuclear accredited.

Mintdale Engineering Mintdale Engineering are a family run business that have been supplying precision engineered parts to clients throughout the UK and internationally in a variety of industries for over 40 years.

experts discussing the key issues and trends that are driving innovation and shaping the UK’s industrial landscape in 2022: from the latest developments in key technology areas such as hydrogen mobility, electrification, and nuclear fusion to keynote insights on automation, finance and engineering skills.

Speakers confirmed this year include: •

Dave Short - Technology Director, BAE Systems: Innovation in the defence sector

•

Ian Whiting – Commercial Director, UK Battery Industrialisation Centre: Scaling up UK electric vehicle battery manufacture

•

Tony Langtry – Head of Mechanical Engineering, Tokamak Energy: The engineering challenges of nuclear of fusion

•

Hugo Spowers – Founder, Riversimple: Transforming mobility with hydrogen

•

Professor Ric Allot – Director of Business Development, STFC: Industrial applications of Big Science.

•

Professor Chris Tuck – University of Nottingham: Insight from the cutting edge of the UK additive manufacturing research community.

•

Nick Hawker, CEO and co-founder, First Light Fusion on the commercial application of nuclear fusion

•

Martin Little, commercial director, Rail Alliance on the overlooked opportunities within rail

Trust Precision Engineering Trust Precision Engineering is an AS9100 for Aerospace accredited subcontract service provider specialising in sliding head machining. The proven cost savings of 1 hit machining for both simple and complex components is fundamental to their philosophy. Trust Precision will competitively provide the highest quality for your machined component requirements.

Shaping the future: Free conference sessions Visitors can also enjoy over 30 hours of free conference sessions lead by industry

Jason Dante, event director for Subcon, points out that this wide range of opportunity and the chance to see so many diverse companies is no accident: “With Brexit, Covid-19 and the ongoing conflict in Ukraine, we are even more aware than ever of the pressures on UK engineering and manufacturing businesses, so we have crammed as

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much value into the event as we can. This year, alongside the Engineer Expo and Manufacturing Management Show theatre, we also have a brand new supply chain theatre that will bring together an expert line-up of speakers to talk about the biggest challenges and opportunities for the sector.

We also once again have ensured there will be ample networking opportunities available at the show, including the VIP buyers lounge, sponsored by Qimtek.

Plus, there will even be a couple of extra surprises in celebration of the Jubilee! We are incredibly excited to include so much new material and look forward to opening the doors at the NEC.”

Sponsored by: |63

Intelligent signalling device NIMU

Stop unnecessary downtime with non-invasive signalling systems Throughout the chemical sector, processes operating at high temperatures and with highly corrosive process media are common. Traditional signalling devices were not always compatible with such conditions and therefore are often over-looked as an additional accessory to monitor the status of the rupture disc.

Fig. 1: Signalling device NIMU (Non-Invasive Monitoring Unit)

Manufacturing PDATE

D

evelopments in technology mean even companies in this sector can now use rupture disc signalling systems, helping not only improve productivity and safety but also supporting with environmental concerns. German manufacturer, REMBE, is the European leader in the manufacturing of pressure relief devices and explosion safety systems and their product range encompasses some of the most robust rupture discs and signalling solutions available to add significant operational value within the chemical industry.

Here REMBE discuss how its intelligent signalling solutions will keep you informed about the status of your entire plant while not being affected by the harsh operating conditions.

For processes operating with potentially harmful media the ability to shut down the process quickly and safely mean the risk of leakage is eradicated.

Complying with explosive atmospheres and intrinsic safety industry standards, the signalling devices are designed to provide rapid notification of rupture disc activation, helping ensure safe management of the process while minimising downtime. REMBE’s signalling devices can easily be integrated with customers control systems to provide visual or acoustic notification of disc burst or to shut down the plant where required.

With non-invasive signalling devices, which make it impossible for the process medium to escape, processes with critical pressures and demanding continues....

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T +49 2961 7405-0 hello@rembe.de

Made in Germany

Your Specialist for

EXPLOSION SAFETY and

PRESSURE RELIEF SOLUTIONS

© REMBE® | All rights reserved

Consulting. Engineering. Products. Service.

Gallbergweg 21 | 59929 Brilon, Germany F +49 2961 50714 | www.rembe.de

June 2022

media can also be reliably monitored. The following text explains the non-invasive monitoring unit NIMU in more detail.

Stop unnecessary downtime

Manufacturing PDATE

For customers for whom compatibility with harsh operating conditions is of paramount concern the NIMU (Non-invasive monitoring unit) is a reusable rupture disc signalling system designed for rapid notification of rupture disc activation even in the harshest chemical environments. The REMBE NIMU sensor is not in contact with the process meaning it is not affected by challenging process conditions or corrosive media.

The intrinsically safe NIMU is installed into a tapping within the outlet of the rupture disc holder, completely isolated from the process so it does not create any leak paths and is not damaged following disc activation - critical for chemical customers where leak paths cannot be tolerated.

With the traditional membrane type signalling devices, false alarms were unfortunately common place, as the harsh operating conditions could cause the device to activate even if the disc itself had not opened. This false signalling would cause unnecessary and costly process downtime. Unlike

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ENGINEERING PDATE

these traditional devices, the NIMU is not negatively affected by the process.

Additionally, membrane detection systems are single use, meaning additional replacement costs.

With the NIMU this additional cost is eradicated – the NIMU enhances overall dependability of rupture disc installations while reducing longterm expenditure. Not only is the signalling device fully reusable following disc functioning it is also reusable after routine maintenance checks. Easy to inspect during such maintenance routines, its closed circuit design allows it to be refitted into the holder by the same operator inspecting the disc, simplifying and quickening the maintenance process, a must to meet the demanding productivity requirements within the chemical processing sector.

When used in combination with the REMBE IQ Safety Cockpit the operator can be instructed in the event of a system disruption and can implement the relevant emergency management protocols. The affected employees can be individually informed of a process shutdown and co-ordinated response to identify the cause and get the plant back up and running as quickly as possible.

www.rembe.de

Leaders in temperature measurement

Hand Held Instrumentation Heading 3

A selection of hand held instruments for many applications including a large range of digital thermometers, light level meter and a range of great value handheld sensors.

IR Industrial IR Medical Infrared Thermometers Thermometers

Pressure Manometers

Digital Light Meters

Anemometers

Temperature & Wood Moisture Meter Humidity Meter

Grain Moisture Meter

www.labfacility.com Bognor Regis tel: +44 (0)1243 871280

sales@labfacility.com Sheffield tel: +44 (0)1909 569446

“It is not worth taking proper pictures here, the environment is too…”

You can complete this sentence with as many negative adjectives as you like, some unprintable! In my 30 years plus as a professional photographer I have heard many … ‘it’s too dark’, ‘too busy’, ‘too dangerous’, ‘too old and worn’, ‘too secret’, ‘too scruffy’.

Yet all companies are compelled to compete and promote themselves and, in our digital age, that means in pictures as well as words. So what to do? An approach taken by some is to find out who has the best camera on their phone and send them along to do the deed. From the selection of poorly lit and badly composed phone pictures, one shot is selected and trundled out on to social media and the company web site.

Industrial sites are a haven for reflective surfaces. Avoiding unwanted reflections, especially self portraits, is vital

Manufacturing PDATE

Shining Light on the Drama of Industrial Environments Adrian Waine, an award winning industrial photographer, shows how rugged industrial environments are worthy of good photography and can be transformed into outstanding images which turn heads and get your company noticed for all the right reasons.

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Yes, some money has been saved and you got that social post done. However, you don’t know how much you might be losing because those pictures are not making your business look like the skilled, expert, professional engineers that you are. You are not yet aware that when you need a large version of that picture for your exhibition board, the poor quality image only enlarges the gap between how you want to be seen and the perception you will actually create.

Poor pictures will never open the door of an opportunity to make the front page of your key trade publication – such as the one in this edition of Manufacturing Update. In short, a quick snap for a quick view and to be quickly forgotten.

Good Images Turbo Charge Your Marketing Professional photography is an investment. A library of high quality images, kept up to date, is an enabler.

It allows you to take advantage of marketing opportunities quickly because you always have something to draw upon where your competitors may not. In time, this pictorial record is your history – a valuable resource that will find new uses as new digital technologies emerge.

So what, you work from an industrial building that might be over a hundred years in use! We see it as a dramatic

and charismatic backdrop. Dark? It just needs some sympathetic lighting.

Works around the clock? Well, that is just a matter of timing and the right preparation to fit with production. In fact, all you need for ‘proper pictures’ in an industrial setting like yours is a ‘proper photographer’. One who understands these difficulties and knows how to overcome them easily to create striking images that ‘pop’ wherever they are seen – print, online, video, in the boardroom or a large exhibition board.

Painting with Light

Understanding light is fundamental.

Problems of mixed lighting are overcome with the right equipment. Using multiple high powered flash units, lighting can be arranged to generate a sense of drama and texture. The aim is to spotlight the subject and lead viewers into your world and see anything but the everyday and ordinary.

The furnace pictures you see here are from a shoot at one of Wallwork’s vacuum furnace halls and shows that such a hard-working environment can be transformed into some sensational head turning images. And yours can too! Review your photo library. Is it up to date? Are the images good enough in this digital savvy age? Are they working

Lit with white light, including smaller flashes under these three large vacuum furnaces creates a dramatic 3D effect.

Same picture now adding warm light to give the heat treatment and introducing subjects to tell a different story

for you? As a professional industrial photographer, I know that however difficult you think your environment to be, there is a great image in the making.

Tackle your subjects with cracking lighting and you’ll have a set of images which keep the publicity fire stoked

far longer that you thought possible.

Coupled with this, Ainsworth Maguire PR can add the crafted text. Let them make headlines for you with their knowledge of engineering and manufacturing. It’s a positive combination that can blend words with imagery and put you on the road to progress.

Manufacturing PDATE

A recent commission from PR experts Ainsworth Maguire, shooting for Wallwork Heat Treatment, illustrates my point. Their Manchester site is one of the largest heat treatment facilities in the UK. Serving aerospace, motorsport, medical and other precision industries, their working environment is 24/7.

Much of their work is subject to non disclosure agreements. They have sites around the UK, some modern while others have had an 80 year plus working life. Lighting is mixed, skylights, sodium, strip and spots.

To see more of our work visit the Photography for Industry gallery at www.photographyforindustry.com/gallery Adrian Waine, Photography for Industry Tel: 0151 356 3855 Adrian Maguire, Ainsworth Maguire PR Tel: 0161 408 7888 Yellow background light focuses attention on the subject.

June 2022

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ESI ESI Technology Technology

Limited

DIGITAL PRESSURE MEASUREMENT SOLUTIONS Discover our newest range of digital pressure measurement solutions. With RS-485 output.

www.esi-tec.com

Railtex / Infrarail showcased the full potential of the railway industry From 10 – 12 May 2022, Railtex / Infrarail took place at Olympia London. The UK’s number one event for the rail industry brought together a total of 3,707 industry professionals, mainly from the UK. With topics from decarbonisation, investments to create a more sustainable rail industry to the digitalisation of rail transport, the exhibition once again showcased the full potential of the railway industry and provided a central meeting place.

“More than 3,700 attendees from management, engineering, planning and technical design backgrounds came to the iconic buildings at Olympia London to create meaningful collaborations and form the future of railway. We are proud to be a part of this again and to support the rail industry’s progress in the modern, post-pandemic world.” says Olaf Freier, Railtex / Infrarail Portfolio Director, on behalf of Mack-Brooks Exhibitions.

Manufacturing PDATE

A total of 130 exhibiting companies from 14 countries with strong involvement from the UK and from countries including Turkey, Italy, Germany, the Netherlands and Switzerland showcased a wide variety of new products and innovative technologies. The focus for this year was clear: Greener and sustainable product solutions, decarbonisation and digitalisation.

Both exhibitors and visitors were highly satisfied with their newly established business relations.

Richard Lenthall, the Vice President of voestalpine Railway Systems mentioned, “Railtex / Infrarail 2022 provided not only the opportunity to reconnect with our customers in person, but we also had a chance to meet new ones. During the three show days, we were able to update our customers on new products where they could see them in person, and without a doubt, this process would not be the same over teleconference. Also, the exhibition provided the perfect stage for business conversations to happen and to engage with quality customers in person.“

Extensive supporting programme Across the three days, visitors and exhibitors of this year’s show had the opportunity to attend a rich supporting programme, including keynote speakers from leading industry names, technical seminars, project updates and Q&A sessions covering current topics for the railway industry. The programme included two conference streams: The Future Focus Conference and Unlocking Innovation, two recurring features organised by the exhibition’s main show partner RIA – the Railway Industry Association.

During Tuesday’s Opening Ceremony, Nicola Hamann, Managing Director of

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Mack-Brooks Exhibitions, welcomed all attendees and expressed her gratitude for joining Railtex / Infrarail 2022 and making this edition a huge success. The opening ceremony carried on with a message from Darren Caplan, Chief Executive at Railway Industry Association (RIA), expressing their views on the future of the industry.

Bill Esterson MP, Shadow Minister for Business and Industry, Simon Blanchflower CBE, Non-Executive Director and Strategic Advisor at FICE and Helen McAllister, Programme Director at GBRTT, were also present to share insights about the latest developments within the railway industry.

In addition to the conference programme, RIA’s Meet the Buyer programme once again offered networking opportunities to participants. Furthermore, the product demonstrations and the on-track display were popular features of this edition.

Date of the next show As the one-stop-shop for the entire railway sector and central platform for companies to showcase their latest products, Railtex will continue to play a key role in the light of the current industry developments. Many exhibitors at this year’s show have already announced that they will exhibit again at the show in 2023. The next edition of Railtex will take place from 9 – 11 May 2023 at the NEC, in Birmingham.

About our railway shows

Manufacturing PDATE

Organised by Mack-Brooks Exhibitions, Railtex / Infrarail is part of a series of targeted trade events for the railway industry, including SIFER in France and EXPO Ferroviaria in Italy, all dedicated to support the recovery of the European rail market.

Altogether, the exhibitions form a network of 25,000 visitors, 40 industry partners and 1,300 exhibiting companies promoting innovation in rail-bound mobility.

June 2022

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Interroll presents new plug-and-play conveyor platform for automated production environments

Manufacturing PDATE

With the new Light Conveyor Platform (LCP), Interroll is expanding its range of products with a platform-based material-flow solution that significantly increases the productivity of manufacturing processes. Designed as a plug-and-play modular system, the LCP allows all system integrators to implement scalable belt conveyor sections very easily in order to quickly meet customer-specific automation requirements for material flow. The high quality and availability of this solution is ensured by, among other things, the use of technical products that have already proven themselves hundreds of thousands of times with users worldwide.

Left: Interroll's Light Conveyor Platform (LCP) is designed to transport smaller conveyed goods, as well as boxes or polybags weighing up to 50 kilograms.

Right: Interroll's LCP offers perfect conditions for decisively increasing the productivity of production cells as well as assembly and packaging stations through efficient material feed and discharge.

Efficient material feed and discharge play a crucial role in realizing the productivity potential of manufacturing cells, assembly and packaging stations. At the same time, rapidly changing process environments in many other industries require flexible conveyor solutions that can easily adapt to new requirements. This is what the Interroll’s new material flow solution for system integrators and plant engineers achieves: Corresponding LCP-based belt conveyors can be easily assembled from factorypreassembled and predefined modules without any engineering effort, and can be put into operation quickly and safely via an autonomous machine control system, optionally without an additional programmable logic controller (PLC). Depending on customer requirements and application, however, connection to an external PLC with user-specific programming is also possible.

very easily and conveniently on the PC monitor using Interroll's popular Layouter tool. This drastically reduces project lead times and the necessary effort for system integrators. In addition, the predefined module sizes in different lengths and widths create the best conditions for fast production and delivery times.

Interroll's LCP is designed to transport smaller conveyed goods, as well as boxes or polybags weighing up to 50 kilograms. The conveyors, which can also handle inclines or declines, are driven by compact and energy-efficient drum motors that have an efficiency of over 85 percent, keeping energy consumption and energy costs very low.

The fully modular system can be planned and assembled

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During the development of the new platform, great importance was also attached to maximum workplace safety and a pleasant working environment. The new LCP was extensively tested before market launch, subjected to extreme endurance and load tests, and developed according to Design for Manufacture and Assembly (DMFA) standards. It features an integrated emergency shutdown at the push of a button, complies with all relevant safety regulations and has a quiet noise level during operation.

The LCP is produced at Interroll's site in Hvidovre, Denmark, and is available immediately in Europe, and soon in Asia and the Americas.

Detailed product information can be found at: https://www.interroll.com/products-solutions/unithandling/conveyor-modules/light-conveyor-platform/.

The new Interroll Split-Tray Sorter Fast, flexible sortation for everyone Interroll introduces the new Split-Tray Sorter: the perfect solution for small and mid-sized items.

Efficiency and low maintenance make this new sorter attractive for those looking for lower operating costs and quicker return on investment.

It is an ideal solution for the 3PL , E-Commerce, Fashion and CEP industries.

Easy to install and reliable with its proven mechanical components & integrated control solution Lightweight and energy-efficient - with a single motor every 40 meters Compact but dense footprint with plenty of destinations Extremely quiet with only <70 dB(A) noise levels

Interroll Limited Unit 1a Orion Way Kettering, Northants NN15 6NL Tel. +44 / 15 36 31 27 70 Email: gb.sales@interroll.com

interroll.com

Specialist Hand & Eye Protection for the Engineering Sector MCR Safety Europe is a long-established manufacturer of specialist hand and eye protection catering extensively for the Engineering Sector. This article outlines just a few products from their range that offer great safety benefits across many different aspects of engineering.

Goggles & Face Coverings MCR Safety are experts in the field of protective eyewear, their range extends beyond spectacles to include sealed unit goggles and full face coverings. Here we see just two examples:

Learn more about Goggles Learn more about Face Coverings

The Hydrobast Goggle is designed and manufactured by MCR Safety. It’s a premium product offering vital protection from liquid / molten splash and dust particles. Plus it has MCR’s Anti-Fog feature to prevent mist and condensation.

XO Skeleton Headgear has an integrated one piece polycarbonate face shield with great optical quality. It protects the wearer's eyes and entire face, it’s scratch-resistant and adjustable for comfort.

XO Skeleton

Hydroblast Goggle

Oil & Moisture

Barrier Gloves

Contact with oil, grease and moisture is unavoidable in many fields of engineering. It can lead to poor grip, certain dermatological conditions and various other hazards.

Tornado Gloves is part of the MCR Safety Family. Their Oil-Teq range includes two gloves, both provide a barrier against oil and liquid at different protection levels.

Oil-Teq 1

Oil-Teq 1 has a fine construction for precision handling.

Oil-Teq 5 is more robust with cut protection at EN388 level ‘C’ and additional reinforcement between thumb and forefinger.

GP1005LD is an MCR Safety glove specially designed to cope with damp working conditions when tools and materials are difficult to handle hence creating hazard. The double layer of latex coating forms a barrier against moisture penetration.

All three gloves have maximum abrasion resistance and offer great comfort and dexterity.

Learn more about Oil & Moisture Barrier Gloves.

OIL-TEQ 1

OIL-TEQ 5

We Protect People.

GP1005LD

‘Second Skin’

for Precision Handling

Contour Air is a ‘Second Skin’ glove developed by the technicians at Tornado, a brand within the MCR Safety portfolio. It’s highly dexterous, designed for precision handling tasks where natural fingertip sensitivity is essential.

Contour Air

Manufactured using state-of-the-art 18-gauge machines and an ultra-fine nylon yarn, it’s light as a feather yet incredibly strong.

GP1006 is a precision handling glove available in a choice of three different coatings with different features and benefits, all manufactured using COOLMAX® Fibre Technology. This is a unique yarn composition designed to prevent clammy hands and enhance dexterity.

COOLMAX® is scientifically proven to transport moisture away from the skin to keep the glove wearers hands cool hence reducing perspiration and optimising performance.

GP1006

Learn more about COOLMAX® fibre

Advanced Yarn Technology

for Reliable Cut Protection CT1062, 63 and 64 offer medium EN388 level ‘B’ cut protection right through to level ‘C’ and ‘D’ at the high end of the scale.

They are manufactured with MCR Safety‘s advanced new yarn technology which is completely free from glass fibre. This means they’re extremely comfortable; they’ve even been described as ‘pure luxury’ in a safety glove.

For great choice and task adaptability, each glove in the range is available with different coating options including Nitrile Air for breathability, PU for dexterity or Nitrile Dual for oil and liquid resistance.

CT1062

CT1063

CT1064

Learn more about MCR Safety’s Advanced Yarn Technology

Prescription Safety Eyewear

Online Ordering & Management

If you manage corporate PPE, EyeTicket from MCR Safety could be a real ‘game-changer’ for you.

It’s an online ordering and management system for prescription safety eyewear. It’s completely paperless and in just three easy steps you can raise a prescription eyewear order for an employee. You can even manage multiple teams across different sites from one single location. In these times of remote working, it could even be from your own home.

EyeTicket completely replaces the traditional paper order form. Your employee will receive notifications via text message or email. All they need to do is book an appointment with their chosen optician, present the text or email confirmation when they make their visit and leave the rest to the Optician.

Because there’s no paper, it’s environmentally friendly too – good news for your green credentials.

Learn more about EyeTicket

www.mcrsafetyeurope.com

MCR Safety Europe.

Middlemore Lane West - Walsall - WS9 8BG - United Kingdom t: +44 (0) 1922 457421 e: sales@mcrsafetyeurope.com

From downtime to uptime Manufacturing PDATE

The need for predictive maintenance

“If it ain’t broke, don’t fix it” is a catchy phrase, but it’s not a good rule of thumb. Unscheduled downtime and poor asset quality costs manufacturing and process industries an estimated $20 to $60 billion each year. Unfortunately, such reluctance to embrace new technologies, due in part to the upfront cost, has hindered progress in operations. Here Neil Ballinger head of EMEA at automation parts supplier EU Automation, explains why maintenance technologies can boost a plant’s profitability through increased uptime.

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Predictive maintenance is a way to predict every possible hardware failure scenario, identifying when maintenance is required and alerting maintenance staff, when necessary, as well as providing preventative solutions.

Anyone who operates within the manufacturing ecosystem will understand that failures and breakdowns happen day in, day out. The intention of predictive maintenance is not just to prevent or reduce these breakdowns, but to help manufacturing plants achieve high-efficiency standards and deliver quality products in the process. A predictive maintenance program can reduce unexpected failure by up to 90 per cent, almost eliminating breakdowns.

To perform predictive manufacturing effectively, the plant manager should gather as much data as possible.

This is crucial when implementing any preventative maintenance strategy, as the more data available to be analysed, the more accurate breakdown predictions will be.

Sensing danger A starting point would be to use smart sensors. Smart sensors, coupled with machine learning algorithms, help to detect anomalies in industrial machines. For example, smart sensors collecting data in industrial IoT environments can keep track of temperature, identifying worn components such as malfunctioning electrical circuits.

Likewise, specialist smart sensors can perform vibration analysis on a particular component, identifying any cases of misalignment, bent shafts or other motor problems. From this data, manufacturers can perform an analysis of the critical assets to establish failure modes. Here, the focus is on the frequency of failures, severity of machine failure and the difficulty of identifying failure.

By connecting condition monitoring devices to a CMMS, plant managers can set up alerts to inform maintenance staff of any faults or anomalies in the equipment. This provides the opportunity to plan for scheduled maintenance when parts need replacing, removing the chance of a serious breakdown from occurring.

For example, sensor technology can be integrated with several different low-level fluid power products — from connectors, hoses and tubing to pumps, motors, actuators and filters.

Here, some of the diagnostic data generated from control valves could be vital in troubleshooting power issues.

Recent machines usually come with different options for realtime data acquisition, but legacy equipment can also be retrofitted with inexpensive add-on sensors.

Predictive maintenance can be a vital asset when dealing with ageing assets, which require careful planning to source obsolete spare parts.

This is where expert consultants at automation parts suppliers, like EU Automation, can help source parts and assist plant operators in their predictive maintenance journey.

While some extent of equipment failure is inevitable, it should not cause unscheduled downtime and poor asset quality, costing manufacturing and process industries billions each year.

Instead, a fully-fledged and effective predictive maintenance plan will help to prevent and reduce downtime significantly, simultaneously boosting a plant’s profitably through increased uptime. www.euautomation.com/uk

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Manufacturing PDATE

W

hile they may be inevitable, equipment failures should not cause serious downtime, eat into profits or make manufacturers overspend their budgets. Today’s manufacturing facilities are far more complex than ever before, consisting of data networks, integrated hardware and a host of automated systems. As a result, most manufacturers do not have sufficient maintenance methodologies in place.

In fact, a report from Infraspeak states that 93 per cent of companies consider their maintenance processes to not be very efficient.

Directory

Manufacturing PDATE

T&D Corporation Mr Minoru Ito, European Sales Office, Gronauer Straße 1, 61194 Niddatal, Germany 0049 (0)6034 930970 europe.office@tandd.de www.tandd.com

Unit 3A, Whitworth Court, Manor Park, Runcorn WA7 1WA. Tel.: (0044)-330 002 0640, sales@odu-uk.co.uk www.odu-uk.co.uk

Curtiss-Wright Surface Technologies

TR Fastenings LTD

European Corporate Office, Hambridge Lane, Newbury, Berkshire, RG14 5TU 01635 279621 www.cwst.co.uk eurosales@cwst.com

Trifast House, Bellbrook Park, Uckfield, East Sussex, TN22 1QW Free phone: 08454 811 800 E-mail: sales@trfastenings.com www.trfastenings.com

Phoenix Mecano Ltd

Blackfast Chemicals Ltd

26 Faraday Road, Aylesbury, Buckinghamshire, HP19 8RY +44 (0)1296 611660 www.phoenix-mecano.co.uk

Unit 5 Russell House , Molesey Road, Walton-onThames, Surrey, KT12 3PE 0207 339 7370, sales@blackfast.com www.blackfast.com

Monitran

Ecopac (UK) Power Ltd

Monitran Ltd, Monitor House, 33 Hazlemere Road, Penn, HP10 8AD, UK T: +44 (0)1494 816569 E: info@monitran.com www.monitran.com

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ODU-UK LTD.

June 2022

Unit 4, Ridgeway, Crendon Industrial Area, Long Crendon, Bucks, HP18 9BF Tel: +44 1844204420 www.ecopacpower.co.uk

Directory

Foremost Electronics Ltd

Seepex UK Ltd.

14 Bluegate Business Park Great Bardfield, Essex CM7 4PZ TEL: +44 (0) 1371 811171 FAX: +44 (0) 1371 810933 WEB: www.4most.co.uk

3 Armtech Row Houndstone Business Park Yeovil, Somerset, BA22 8RW

0-12 Caxton Way, Watford Business Park, Watford, Hertfordshire, WD18 8JY www.hrs-heatexchangers.com Email: info@uk.hrs-he.com Tel: +44 (0)1923 232 335

Mecmesin Ltd Newton House, Spring Copse Business Park, Slinfold, West Sussex, RH13 0SZ w: www.mecmesin.com t: +44 (0) 1403 799979 e: info@mecmesin.com

1 Brownfields Court Welwyn Garden City Hertfordshire, AL7 1AJ www.rotechmachines.com

BÜLTE GmbH Kunststofferzeugnisse Carl-Sonnenschein-Straße 22 D-59348 Lüdinghausen – Germany Phone: (+49) 02591 / 91 94 – 0 info@bulte.de www.bulte.com

Wood Automated Systems UK (ATG – Systems) Tenter Road, Moulton Park Industrial Estate Northampton, NN3 6AX +44 (0)7827 327231 Tim.Bednall@woodplc.com www.the-atg.com

Lascar Electronics Ltd UK Module House Whiteparish, Wiltshire SP5 2SJ +44 (0)1794 884 567 sales@lascar.co.uk www.lascarelectronics.com

Rotech Machines Limited

June 2022

Manufacturing PDATE

HRS Heat Exchangers

T +44 1935 472376 sales.uk@seepex.com www.seepex.com

23

SICK’s Fill Level Monitoring Keeps Packaging Machines Topped Up

Manufacturing PDATE

A digital service that gives instant visibility to filling levels in packaging machinery has been developed by SICK in collaboration with industry end-users. SICK Filling Level Monitoring avoids machine stoppages by giving real-time data to operators via smartwatch or phone, so that levels of carton blanks, adhesive or film wraps, for example, stay topped up.

24

June 2022

I

nstead of having to check each magazine or film roll level in person, machine operators monitor fill levels on their watch or phone and are alerted by SICK’s Filling Level Monitoring system before levels become critical. Machine downtime is avoided and staff walking routes can be planned efficiently to ensure optimum production uptime.

Industry Collaboration

The SICK Filling Level Monitoring cloudbased dashboard provides easy-tointerpret graphical information about the real-time status of machines from any internet-enabled device. Automatic push notifications on the fill levels can be set up for smart devices to alert with an acoustic signal and vibration. Meanwhile, production managers can monitor the fill levels of all machines across a packaging line, shift or entire production

facility. Analysis of historic trends can be used to optimise production processes.

Unexpected Benefits Neil Sandhu, SICK’s UK Product Manager for imaging, measurement and ranging, said: “SICK worked closely with leading packaging end-users and machine builders in Europe to develop a cost-effective and easy-to-implement system.

“By using the smart watch alerts, our customers found that fewer operators were needed to keep cartoning machines replenished, so staff could be deployed more efficiently to other duties. What’s more, the system brought unexpected benefits to overall production control.

For example, the loads on packaging machinery lines could be monitored to identify over- or under- capacity.”

While initially developed for cardboard and film packaging materials, Filling Level Monitoring can also be adapted for liquids including adhesives, or granular raw materials. It is also possible to add customised services and analyses tailored to particular machinery or processes.

Up to six SICK sensors can be monitored by each SICK SIM1012 gateway, and more sensors, including third-party devices, may be added by connecting over OPC-UA. Sensors are also

continuously monitored by the system in case one should go offline or need a replacement.

The solution can be extended to meet the needs of customers on request, e.g. to customise and display additional data on the dashboard. Integration to third party ERP and MES software systems is also possible.

Digitilisation Neil Sandhu concludes: “Cloud-based services such as Filling Level Monitoring illustrate how making reliable sensor data transparent enables digitalised machine operation as part of Industry 4.0. By combining smart sensors with intelligent software, critical processes can be visualised in real time and adapted for the needs of users.

“Early adopters are noticing new and unexpected production trends when they view and interpret their historical production data in easy-to-read graphical displays. As a result, they have been able to optimise production processes and deploy staff to achieve efficiencies never even expected.”

www.sick.co.uk

June 2022

25

Manufacturing PDATE

The SICK Filling Level Monitoring digital service can be used with any SICK smart level sensors. Its first applications have been developed with packaging manufacturers and machine builders using SICK DT-50 laser distance sensors to output level measurements from carton magazines and film rolls.

The measurements are routed to a SICK SIM1012 edge gateway, which aggregates and forwards encrypted data via SICK’s LiveConnect digital interface, so that it can be easily accessed, managed, and processed online.

123 Insight releases more free MRP educational videos 123 Insight has released six additional videos to its free MRP educational video series on YouTube, bringing the total number of videos available currently to 15.

T

he videos are designed to help manufacturing companies that are either struggling with paperbased, Excel-based, or home-grown database systems to manage stock control, purchasing, or planning, or that are considering moving away from an existing MRP/ERP system that no longer meets their needs.

Manufacturing PDATE

Each video is around 3-4 minutes in length and is designed to give the viewer a basic overview on each subject.

The latest videos include: • What is a Bill of Materials (BOM)?

• Batch production and MRP systems • What will MRP do for your sales department?

• What will MRP do for your purchasing department?

• What will MRP do for your stores department?

• What will MRP do for your production department?

26

June 2022

These join an existing array of videos including common MRP/ERP implementation mistakes, the top 20 benefits of an MRP system, a brief history of MRP and how MRP and Lean Manufacturing can work together.

Simon Badger, Managing Director of 123 Insight said; “Many smaller manufacturers start out with what they believe are perfectly manageable systems in place, but as they grow, they quickly discover a lack of efficiency, visibility and traceability. We’re creating these videos as part of our educational approach to MRP selection and implementation, empowering companies to understand what a well-implemented MRP system should be doing for their business, but without all the traditionally associated up-front massive financial commitment.”

Companies can find 123insight on YouTube or visit 123insight.com for more information. 123 Insight also run regular online educational MRP events, which are free to attend. Attendees will also receive a free book on how to implement an MRP system.

Considering manufacturing so�ware?

Two online ways to evaluate MRP

INFO Exchange

Evalua on Workshop

A �uick so�ware overview Good introduc on to MRP Typically a larger group

In-depth so�ware walkthrough Q&A session a�erwards Typically a smaller group

See what a manufacturing system should be doing for your business.

Whether you are considering manufacturing so�ware for the first me or looking to replace an exis ng system, we have created two online events to help you gain a be er understanding of what MRP can do for your business, in terms of efficiencies, cost savings and traceability.

The INFO Exchange gives you a taster in 50 minutes, allowing you to see the 123insight so�ware and MRP in ac on. The 2½ hour Evalua on Workshop gives you a deeper look with a Q&A session at the end, allowing you to make a decision and move forward. You will also receive a free copy of our book ‘How to implement a manufacturing system’ just for a ending.

Alterna vely, register to get access to our online Demo Movies, broken down by job role, which explain what 123insight will do for each department in your business.

Book to a end at 123insight.com Advanced Simplicity ®

123 Insight Limited

01489 860 851 info@123insight.com www.123insight.com

Free book on implemen ng MRP when you a end.

Features Include:        

PLC Web Browser OPC UA Server WebView In Excess of 300 Communication Drivers Event Bar Chart Database Server SQL Query Energy Demand Display/Setting

sales@lamonde.com www.lamonde.com +44 (0)20 3026 2670

Lamonde Automation Limited Quality Products: Expert Advice