Manufacturing Update - November 2021 by jetdigitalmedia

MANUFACTURING PDATE www.manufacturing-update.co.uk

November 2021

MORE THAN CLEAN

“ The Highest Product

Quality with SEEPEX low shear EHEDG pumps.”

See pages 10 & 11

3 & 4 November 2021, NEC Birmingham The UK’s leading annual gathering of engineering supply chain professionals

SAVE THE DATE I found the event a great networking opportunity to meet industrial professionals from different backgrounds with different products. Kat Clarke, Wing Manufacturing Engineer, Airbus

10,000+ engineering professionals in attendance

500+

exhibitors showcasing their products/services

200+

hours of free-to-attend industry content

Benefit from co-location with: AERO ENGINEERING

AUTOMOTIVE ENGINEERING

PERFORMANCE METALS ENGINEERING

COMPOSITES ENGINEERING

CONNECTED MANUFACTURING

MEDICAL DEVICE ENGINEERING NEW

NEW

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.

MANUFACTURING PDATE www.manufacturing-update.co.uk

November 2021

MORE THAN CLEAN

“ The Highest Product

Quality with SEEPEX low shear EHEDG pumps.”

See pages 10 & 11

November 2021

Publishing Director

Editorial Assistant

Publishing House

Jodie Little 01843 448 443 jodie@jetdigitalmedia.co.uk

Taylor Owens 01843 448 443 taylor@manufacturing-update.co.uk

Publication Manager

Production

Tim Johnston 01843 448 443 tim@manufacturing-update.co.uk

Chris Sims 01843 448 443 chris@manufacturing-update.co.uk

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

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Manufacturing PDATE

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Wait or Hold?

Manufacturing PDATE

Warehouse and production operations use buffer systems when their processes include a wait or hold step, material handling process requires reserve inventory to manage fluctuating demands, or when there’s a requirement for a quick and accurate order consolidation process before shipping. Without the proper buffering system in place, warehouses often waste space, and experience longer travel and search times than necessary. Using automated technology will require up to 85% less floor space than a traditional rack or shelving system. Common buffer systems such as miniload and bin-shuttle systems manage buffer inventory well but they come with a hefty price tag. While these solutions work for larger operations, they are unable to scale down to handle smaller volumes cost effectively. Vertical Buffer Modules (VBMs) are uniquely designed to maximise storage capacity and manage items in a compact footprint. They buffer 500 - 2.000 totes and are both, cost and energy efficient. Implementing the LR 35 for automated buffering provides multiple benefits

November 2021

such as buffering for small parts in a fast and efficient manner. Eliminates operator travel time and minimises storage footprint. There are two types of buffer that can be utilised by using the LR35: Consolidation Buffer: To consolidate orders quickly and accurately before shipping or packing the use of a the LR 35 using Java Machine Interface (JMIF) software and automated conveyor connection is a Kardex recommended solution. Order bins are scanned, stored, and retrieved when needed without any human intervention. When all items for the order are in the consolidation buffer, the JMIF software notifies the host system and starts the retrieval when needed. Production Buffer: The LR 35 is used in production to buffer goods between individual work steps, avoiding costly interruptions in the operating processes. It’s designed to absorb surplus production and to decouple the process sections, ensuring the highest possible production rate. Production components are mostly transported with an automated conveyor system connected

to the LR 35 or with automated guided vehicles (AGVs). For additional picking, the LR 35 can be equipped with a turntable. Companies without buffer storage may experience waiting times between individual steps. In addition, many warehouses lose valuable space when manually buffering customer orders ready for dispatch in the shipping area. Manual storage on pallets or in static shelves is chaotic, takes up more space than necessary, and requires longer travel distances and search times for personnel. The implementation of an automated buffer system like the LR 35 for intermediate storage and consolidation of orders and goods ensures safe, fast, and smooth material flow in the production and shipping departments. To learn more about how the LR35 can manage your order picking and consolidation requirements click here. Or contact Kardex on 01992 557237, email: info.remstar.uk@kardex.com www.youtube.com/ watch?v=N44wYI6h_FA&t=24s

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

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Anemometers

Temperature & Wood Moisture Meter Humidity Meter

Grain Moisture Meter

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

HMRC reports 16% increase in SME’s claiming R&D Tax Credits* We ask Henry Poultney of R&D tax relief consultants Fiducia to analyse HMRC’s recently published statistical survey of companies claiming R&D tax credits. HMRC’s recently published annual report on companies claiming R&D tax relief once again demonstrates an annual increase in the number of companies claiming this increasingly popular tax relief. Analysis of the financial year ending March 2020 shows a 16% increase in the number of claims for R&D tax relief to a total of 85,900 – with 76,225 of claims being made by SME’s. It is disappointing to note however that, despite year-on-year rises in companies claiming this valuable tax relief since the scheme was introduced in 2001, a significant number of companies who invest in research & development still fail to claim what is rightfully theirs. And nowhere is this more true than in the manufacturing sector. Whilst HMRC’s statistics show that the manufacturing and information & communication sectors lead the way in terms of the number of claims submitted, the actual percentage of manufacturing companies submitting claims is astonishingly small.

Manufacturing PDATE

When you consider that the average value of R&D credits paid to SME’s by HMRC in the year to March 2020 was £57,723, why is it that so few companies that are entitled to claim, fail to do so? To put this into context, a briefing paper published in December 2018 by the House of Commons Library Research Service, suggested there are 290,000 active manufacturing companies in the UK. HMRC’s statistics show that less than 7% (18,898) of these manufacturing companies claimed R&D tax relief in the year to March 2020.

November 2021

HMRC R&D Statistics for 2019-2020 •

76,225 SME’s claimed R&D tax relief

•

Average SME claim value amounted to £57,723

•

16% rise in number of SME’s claiming

•

25% rise in first-time claims from SME’s

•

More than £4.4 billion of tax credits awarded to UK SME’s

When you consider that the average value of claims paid by HMRC in the year to March 2020 was £57,723, why is it that so few companies that are entitled to claim, fail to do so? The reasons are many. Despite the year-on-year increases in take up of the scheme (HMRC reported a 16% rise in first-time claimants in the year to March 2020), awareness and understanding of the scheme remains low. Many business owners who are actually aware of the scheme fail to make a claim – despite the massive cash boost it can create for a business – because the owner is so wrapped up in the day-to-day running of the business that he/she are not able to set aside an adequate amount of time to formulate a claim. (I refer to it as a massive cash boost because of HMRC’s two-year rule that allows companies to backdate claims for their two previous financial years).

For many busy company owners, the major stumbling block to submitting a claim is the need for the claim to be supported by a technical document that defines how their own R&D activities satisfy HMRC’s claim acceptance criteria. And this is where specialist advisers such as Fiducia can take the burden of formulating a claim away from the business owner. With a 100% claim success rate, we can usually determine whether a company’s activities are likely to qualify for the R&D scheme with just one relatively brief telephone call. Check our website to find out more and give us a call to establish if your company qualifies for this valuable tax relief.

www.fiduciaconsulting.com 01244 689311

* Source: National Statistics Research and Development Tax Credits Statistics: September 2021

sales@lamonde.com

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4 Comm ports, inc Ethernet Built-in data logging to microSD Free no-limit programming Slim stackable design Multiple i/o wiring options Starter kit available

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Lamonde Automation Limited Quality Products: Expert Advice

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November 2021 ENGINEERING UPDATE

SICK’s NextGeneration Ruler3000 Offers a Fast Track to Breakthrough 3D Vision Power SICK has unveiled the first in a new generation of Ruler3000 3D streaming cameras, designed to offer a fast track for integrators to harness the unmatched speed and measurement precision of SICK’s high-definition 3D imaging technology. The SICK Ruler3000 sets a new standard for high-speed 3D image quality in an easyto-integrate, pre-calibrated device. The Ruler3000 combines SICK’s groundbreaking Ranger3 streaming camera with a Class 2 eye-safe laser, pre-selected optics and fixed geometries to enable much simpler configuration and commissioning. With industry-standard compliance giving comprehensive access to machine vision software tools, the Ruler3000 dramatically cuts time and complexity when integrating more demanding inspection, measurement and robot guidance tasks across a wide range of industries.

Manufacturing PDATE

“With today’s demands for higher throughputs, more accurate quality control and flexible, batch-orientated production, the pressure is mounting to deliver more speed and accuracy from 3D machine vision systems,” says Neil Sandhu, SICK’s UK Product Manager for Imaging, Measurement and Ranging. “The SICK Ruler3000 is an exciting prospect for OEMs, system integrators and accomplished 3D vision end users. Because so much of the configuration and commissioning work is already done, you can rapidly shortcut to integrating a continuous stream of industry-standard data into higher level systems or robot controls. And, with accurate 3D, reflectance and scattered light measurements in one device, you can evaluate several aspects of the inspection simultaneously to achieve optimum control and measurement confidence.” Powerful Streaming Camera Powered by SICK’s highly sensitive CMOS sensor and innovative ROCC (Rapid

November 2021

On-Chip Calculation) technology, the Ruler3000’s integrated streaming camera scans reliably at rapid production speeds. It processes up to 15.4Gp/s to enable up to 7000 full-frame 3D profiles per second. The Ruler3000 extracts the true 3D shape of an object, regardless of its contrast or colour, as well as simultaneously capturing greyscale and scattered light measurements, so image processing and measurement precision can be optimised. The Ruler3000’s high light sensitivity enables accurate inspection of even very dark or highly-reflective materials, while its High Dynamic Range (HDR) function allows components with widely-differing light remissions such as tyres and shiny metal assemblies to be captured successfully in a single scan. Outstanding Performance The SICK Ruler3000’s outstanding performance on light, dark, reflective and contrasting surfaces, together with its guaranteed field of view, make it ideal for high-end inspection and precise localisation duties, when mounted above a conveyor or on a robot arm. It is therefore likely to find diverse applications in industries including electronics, automotive components, consumer goods, food and beverage and pharmaceutical production. Simple and Versatile Integration Integration is made even simpler by the user-friendly Stream Setup interface. The newly developed SICK GenIStream API facilitates integration for C# and C++ users. Full compatibility with industry standards such as GigEvision and GenICam, provides plug and play access to third party software such as HALCON and LabVIEW. In addition,

developers have all the flexibility of SICK’s AppSpace software development platform with its wide range of image processing tools and application examples. The highly accurate SICK Ruler3020 is the first release in the Ruler3000 product family. It delivers 3D profiles at up to 7kHz full format, or up to 46 kHz with a reduced region of interest. Measurements are output in millimeter values with a Z-resolution from 8-15µm and an X-resolution from 63-88µm, assuring very high definition to inspect even extremely dark or reflective surfaces, as well as to output precision data for accurate robot guidance. Accurate measurement values are assured down to 8 µm in height. The guaranteed field of view concept of the SICK Ruler3020 ensures commissioning is easy. SICK plans to release more variants with differing fields of view during 2021. With a compact design, the IP65/67 SICK Ruler3020 can cope with harsh industrial environments without the need to design expensive protection in the machine. For more information please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk. www.sick.co.uk

3 & 4 November 2021, NEC Birmingham The UK’s leading annual gathering of engineering supply chain professionals

SAVE THE DATE I found the event a great networking opportunity to meet industrial professionals from different backgrounds with different products. Kat Clarke, Wing Manufacturing Engineer, Airbus

10,000+ engineering professionals in attendance

500+

exhibitors showcasing their products/services

200+

hours of free-to-attend industry content

Benefit from co-location with: AERO ENGINEERING

AUTOMOTIVE ENGINEERING

PERFORMANCE METALS ENGINEERING

COMPOSITES ENGINEERING

CONNECTED MANUFACTURING

MEDICAL DEVICE ENGINEERING NEW

NEW

How clean is your closed equipment? SEEPEX hygienic pumps meet the highest food hygiene standards.

Manufacturing PDATE

he SEEPEX EHEDGcertified progressive cavity pump range was born to meet food industry demands for equipment that adheres to strict safety and hygiene requirements without compromising product quality. This range, the BCFH, was the first hygienic progressive cavity (PC) pump to be certified by the European Hygienic Engineering and Design Group (EHEDG) under its revised testing process. This certification guarantees residuefree cleaning at a lower temperature,

November 2021

with both lower chemical concentrations and a shorter cleaning time than is normal for other cleanin-place (CIP) procedures used in the food industry. As well as giving endusers peace of mind that their closed equipment is microbiologically clean, equipment designed to this standard typically requires 76% less cleaning time, saving on water, detergent and energy.

High cost of poor hygiene Product safety is a key concern for manufacturers across a variety of industries, including

pharmaceutical, chemical and food & drink. Contamination by microorganisms such as bacteria, moulds and yeasts is an ever-present risk. Therefore, effective hygiene and cleaning regimes are essential to prevent the build-up of microbes in the processing environment, particularly in closed systems. The financial impact of ignoring this threat is significant – the Association for Packaging and Processing Technologies puts the average cost of a recall for a food company at $10m or more in direct costs, business interruption, brand damage and lost sales.

Left: SEEPEX’s EHEDG-certified pumps with enhanced internal design ensure residue-free cleaning. Below: The ultra-hygienic BCFH pump range has a low shear action, making it ideal for sensitive foodstuffs such as yogurt.

Meeting tough standards The test methods for EHEDG certification are extremely rigorous. In order to meet the required standard, BCFH pumps were used to process food that had been inoculated with microbes. The pumps were then cleaned at a lower temperature than is normal for standard CIP, before being stripped down and tested, to ensure every microbial trace had been removed. Changes to the EHEDG certification process in recent years have made the test even more rigorous, as well as more transparent. Certification is now only valid for five years, and results are also reviewed by independent EHEDG inspectors, in addition to those that carry out the original tests. The current testing procedures guarantee that certification continues to provide endusers with complete confidence that the closed equipment they are using meets the highest possible level of hygienic design.

Ensuring brand reputation As an established supplier of hygienic PC pumps for a wide range of applications involving product transfer with high-care requirements,

SEEPEX understands that food processors must be able to rely on the hygienic credentials of their equipment to produce safe, high-quality products. Not only does this help to reduce waste and lower production costs, it also protects both public health and the brand’s reputation. Hygienic pump design must consider not only the materials used to build the pump itself, but also its cleanability, including surfaces and rotating components. To ensure effective cleaning using CIP there must be no areas that are structurally difficult to clean and no food or microbial residues remaining after cleaning, as these will contaminate subsequent production. Automated product transfer must also be possible without any detrimental effect on product quality, either physically or microbiologically.

Preserving product integrity Thanks to their low shear action, SEEPEX PC pumps maintain a product’s physical quality; even sensitive products such as yogurts, cream cheese, whipped cream or other colloidal mixes. Equally, they can efficiently pump viscous and sticky products, as well as those containing soft solids such as fruit or vegetable pieces. Furthermore, when used for dosing, PC pumps produce a low pulsation flow that has linear proportionality to the pump speed, allowing for easy calibration and greater accuracy. This maintains product quality, even when using a variable raw material.

In addition, the use of PC pumps can help manufacturers to lower their production costs. Alternatives such as rotary lobe or twin-screw pumps create shear, which affects consistency. Additives are then needed to compensate for this shear to ensure that sensitive products, such as yogurts, regain their original consistency. Food producers using low shear PC pumps do not need to add costly additives downstream to restore product texture and appearance.

Increased cleaning abilities All SEEPEX hygienic PC pumps have a special surface finish and are designed to be dead-space free to prevent product from collecting in the pump. However, their hygienic BCFH pump range has a titanium flexible rod as the rotating unit, which is corrosion resistant and low maintenance. Containing no joints, the rotating unit is detachable from both the rotor and the plug-in drive shaft, making maintenance easier.

www.seepex.com

November 2021

Manufacturing PDATE

Likewise, it is essential that adherence to safety and hygiene does not adversely affect the quality of a product. The challenge, therefore, is designing cleaning regimes and equipment that provide the best possible hygienic solutions to ensure product safety without comprising on quality. This is exactly what the SEEPEX BCFH pump range has been designed to achieve.

Autumn is here! --- Time to Karl Lycett – Rittal UK Climate Control Product Manager Finally! The temperature seems to be reducing to a more bearable level, the nights are slowly drawing in and... do I see a hint of colour change in the trees? That’s right Autumn is upon us once again and that can only mean one thing… It’s time to stop, look back at the summer period and understand how things went. Did you see • Electrical equipment under stress? • Unexpected breakdowns? • Emergency repairs needed on critical equipment? If any of this sounds familiar or has happened to you, now is the perfect time to put plans into place to make your life easier when next summer hits. Servicing, upgrading or even specifying some brand-new Climate Control to protect your equipment is one of the most effective ways of creating a protective environment

for your sensitive electrical equipment within your enclosures and ensuring it lasts for many summers to come. Even if your cooling equipment is upto date, there is always an opportunity to make small improvements which will increase your overall efficiency. A great example is the implementation of Industry 4.0 principles, simply put this is taking any data generated by cooling equipment and allowing it to be directly reported into your building management systems or straight to the relevant person in charge of managing the health of your electrical equipment. This reduces the need for daily walk round with a clipboard, making notes of any issues. This old-style approach can result in

Enclosure Climate Control Whatever the scale...... ......we have the solution ENCLOSURES

42|

POWER DISTRIBUTION

CLIMATE CONTROL

reflect things being missed and breakdowns occurring unexpectedly, however, with solutions now available you can choose to have e-mails sent directly to key personnel whenever limits have been reached and warning flags are showing. This means staff are utilised more efficiently and can be safe in the mind that they will be notified if any issues begin to arise. Now never fear, we know that your sole focus doesn’t lie on Climate Control, you have more important things to worry about, mainly keeping your business up and running and producing for your customers. That is where Rittal is here to help. Over the next three months we are going to cover a different theme related to Climate Control but with the focus on how you can utilise this information to get the most out of your equipment, by creating that protective environment and allowing it to thrive and stay healthy. This takes the workload off you when the temperature starts to rise again and allows you to concentrate on more important matters on site while in the back of your mind knowing you have implemented systems to keep your equipment chugging along.

replacement of spare parts etc. If items are tripping out every year, this causes a high level of wear on components which can result in more order being produced to replace burnt out cards etc.. All of these small changes are going to impact your bottom line and overall efficiency. The next Three months topics are going to be as follows, with different media every week to support the overarching theme –

The additional benefits of undertaking this action is the reduction in energy usage and costs related to the

IT INFRASTRUCTURE

September of Cooling

If you feel like any of the topics mentioned above would be of benefit to you, then keep your eyes peeled on our social channels for the contact to begin rolling in September. In the meantime, if you have any specific questions or would like the information sent straight to your inbox, send an e-mail to cooling@rittal.co.uk and one of our colleagues will get in touch to help

--- The Fundamentals

October --- Service & Maintenance of Cooling Equipment November Industry

--- Focus on: Cooling

SOFTWARE & SERVICES

www.rittal.co.uk

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An electronic device looks set to save time, and money for British Manufacturers Adding water to a mix - everything from feeding mixing bowls to filling tanks has long been carried out using pails or hosepipes. Time consuming, open to accident and operator error, there has never been a viable, micro-computer controlled, UK alternative. However, Aquameter Ltd based in Hertfordshire is already changing all that. Their ABACUS digital device delivers exact, pre-selected quantities of water from a single pipe - straight into the mixing vessel. This precise metering of the water means the operator can exactly re-create batch consistency each time Operation of the ABACUS is simplicity itself: the quantity of water required is keyed in, the “start” button pushed, and the water flows. A water solenoid valve located in the water pipe closes the flow at the completion of the cycle; when the pre-set batch quantity is reached. The unit is already in use across the UK and beyond, and is being snapped up by food manufacturers around the globe. Matt Bell, Production Manager with Bell Bakers, located near Glasgow, says of the system: “We use two systems for metering water into the mixers in the main bakery area and one into the boiling pans for stews. Were it not for these units we would be

using buckets of water or a line of hose - not that convenient.” He goes on: “We have control over the whole operation... it’s obviously more accurate; using the meter rather than relying on staff to put it in by pail.” Thanks to a small Hertfordshire company, manufacturers now have the ability to reproduce exact batch consistency each and every time. Call us on 01 992 442 861 Visit our website www.aquameter.co.uk

BESTCONNECT SYSTEMS CAN BE EASILY CONFIGURED AND RE-CONFIGURED TO SATISFY YOUR CURRENT AND FUTURE NEEDS.

+44 1536 206969 SalesUK@fmhconveyors.co.uk fmhconveyors.com

Vibration isolation in high precision manufacturing The benefits of inertia bases and bespoke engineering What is the most effective antivibration technique for machinery? In high precision manufacturing, getting vibration isolation right is especially important as even a relatively small amount of vibration can disrupt the working of sensitive equipment. Here, Adam Fox, director of vibration isolation specialist Mason UK, explains the benefits of inertia bases.

Manufacturing PDATE

Inertia bases are primarily used to support mechanical equipment. They are generally steel frames which are filled with concrete and supported by spring mounts to provide a large stable mass on resilient elements with a low natural frequency to provide a high level of isolation. Different types of bases are used depending on the application. Larger bases might be used for pumps for example, while smaller bespoke bases might be installed for sensitive scientific equipment. Getting the engineering right In many applications, vibration isolation is not simply a case of picking a particular product off the shelf. In many instances, the product needs to be

November 2021

specifically designed for the unique demands of that project. You also need expert engineers who can assist with installation and onsite support. This is especially so in precision manufacturing, or in applications involving the use of sensitive equipment such as blue-chip production, scientific laboratories or medical facilities. In these situations, a good level of vibration isolation is not enough. You often need above 98% isolation efficiency from the disturbing to make sure sensitive equipment performs as it is designed to do. We’ve been involved in a number of such projects. For example, we had to isolate a vertical boring machine to prevent its operation from interfering with precision manufacturing facilities that were located nearby. We designed the bases, which were supported by Mason SLF spring isolators, and handled the installation. On this occasion, we also provided rubber dampers under the slab as part of a bespoke solution. In another instance, we worked on a project where we needed to isolate sensitive ultrasonic equipment

being used in pioneering cancer research. Vibration caused by nearby construction work was seriously impeding the use of this equipment, which operated at very high levels of precision. We had to design and install a steel base support by Mason MT Air Springs. Again, this was a bespoke design to fit the legs of the equipment precisely, as well as fitting within the existing raised access floor. Inertia bases are especially effective at isolating disturbances caused by pumps and to isolate sensitive manufacturing equipment from external vibration sources. However, it is important that they are partnered with the right acoustic isolation products and in many cases, as we have seen, you need a solution that is bespoke. A good acoustic consultant can advise you on this, so make sure you get them involved in your project at the earliest possible stage. Mason UK provides specialist isolation products for a wide range of applications, including mechanical and electrical systems and HVAC isolation. To find out more visit www.mason-uk.co.uk

Precise process monitoring

Hygienic pressure transmitter with IO-Link Interface

RANTY AR

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Whether food or beverage industry, milk production or meat processing: The ifm pressure transmitter, PM, reliably monitors your process, with a high accuracy of 0.2 percent! The excellent temperature compensation allows for rapid temperature changes in the process, eg. In CIP / SIP up to 150° C. This makes the pressure transmitter ideal for demanding applications in the food industry. A free factory calibration certiﬁcate for each sensor is available as a download. Interested? ifm - close to you!

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Seeing is Believing James Mann, Enterprise Business Development Manager at Getac discusses why manufacturers are increasingly turning to Augmented Reality technology to solve operational challenges in the post-COVID landscape. Despite the concept of Augmented Reality (AR) first appearing almost twenty years ago, it’s only recently that hardware and software have reached a point where commercial AR is finally becoming a reality. That said, the timing couldn’t be better. With the COVID-19 pandemic still imposing unprecedented restrictions on global movement, this exciting technology could well hold the key to many of the operational challenges manufacturers now face.

Manufacturing PDATE

WHAT IS AR? AR combines elements from the real world with digital representations. Unlike virtual reality (VR), it does not fully immerse the user in a digitalised world, but rather integrates digital information in the perception of the user, enriching the real-world representation with virtual elements and providing context relevant data. Doing so combines the advantages of both concepts (digital and real-world), allowing for hands-free operation and removing the need for an additional device for entry or display purposes.

WHAT ARE ITS PRACTICAL APPLICATIONS FOR MANUFACTURERS? One of the applications with enormous potential is the maintenance and repair of industrial machinery over large distances. With the manufacturing industry suffering from a growing skills shortage, many organisations have a relatively small pool of skilled experts that they rely on to lead repair operations all over

November 2021

the world. However, ongoing COVID restrictions mean they are currently unable to physically travel, which leaves virtual consultation the only option available. Adoption of AR technology can significantly enhance the quality and capability of long-distance repair work, enabling experts to remotely connect with less skilled technicians from anywhere and walk them through complex tasks step-by-step. Such an approach also offers numerous side benefits. Not only does it enable better knowledge sharing between skilled and lesser skilled employees, helping to reduce skill gaps, it also helps manufacturers cut their carbon footprints (and expenses) by eliminating unnecessary employee travel. At a time when the combination of growing skill gaps and global travel restrictions is putting increasing pressure on manufacturers everywhere, AR technology offers a timely, technology-based solution. As adoption continues to grow (IDC predicts worldwide spending on AR and VR will grow from $12.0 billion in 2020 to $72.8 billion in 2024), it offers one of the best ways to share expert knowledge in a cost efficient and environmentally conscious way. To find out more about Getac’s manufacturing and AR solutions, please visit www.getac.com/en/industries/industrial-manufacturing/

INSPHERE Ltd Launch new flagship product IONA for industrial automation monitoring and control INSPHERE was co-founded by CEO Ben Adeline and CTO Oliver Martin in 2013 to develop the use of data to drive manufacturing process performance. The company works across a range of industries including aerospace, automotive and energy, and with clients such as Airbus, Rolls-Royce, BAE Systems and Jaguar Land Rover to deliver profitability and productivity with their innovative data driven hardware and software solutions.

•

IONA is a network of sensors and software that can simultaneously capture alignment data from industrial robots and other points of interest, be that the work piece, fixture or cell datums. Using IONA, engineers can monitor the performance of automated systems and ensure they are performing consistently in accordance with the simulated or programmed intent. The data generated with IONA can be used to make corrections either as a one-off system calibration or as part of regular dynamic adjustments compensating for natural process variation.

The outputs of IONA are: •

• •

Improved System Accuracy – Allowing more processes to be automated and improving process quality Correction to robot programs – Enabling faster commissioning and validating a digital twin Reduced automation downtime – Enabled by predictive maintenance using IONA SPC trend data.

INSPHERE Ltd announces a flagship new product that will create a step change in the productivity of industrial automation and generate process data to unlock the potential of a wide array of digital manufacturing technologies.

Measurement technologies are typically used at the end of the production line where discovered faults or defective parts mean they are either scrapped or require expensive re-work. INSPHERE’s philosophy has always been to counter this traditional approach and use measurement data to enhance the process so that root causes in the production line can be identified early on and manufacturers can overcome costly downtime and the consequences of poor-quality parts when problems are unresolved. INSPHERE’s growing portfolio of technology operate in real-time, automatically measuring the performance of manufacturing systems and instructing selfcorrection, creating a closed-loop control systems. This not only avoids downtime but also provides significantly quicker line set-up, reducing waste, improving productivity and ultimately enhancing profitability for manufacturers. Industry Demand •

Manufacturing PDATE

•

November 2021

Automation is experiencing significant growth, in part driven by the pandemic and the need to create a step-change in productivity to fuel recovery. With ever shortening new product introduction cycles, manufacturing systems need to be far more flexible to reduce the cost of producing new product variants. Lack of performance of industrial automation is a barrier to realising the full value of ‘Industry 4.0’ technologies that purport to offer a solution to these challenges.

Tel: 01296 611660 Email: rk@pmgb.co.uk www.phoenix-mecano.co.uk 26 Faraday Road, Aylesbury Buckinghamshire HP19 8RU

Polymer Additive Manufacturing – Not just for prototypes Not all polymer 3d printers were born equal. You may be familiar with rough surface finishes, poor material options and run-of the-mill, low-quality prototypes, but the Additive Manufacturing (AM) industry has taken huge strides in material and machine development since the first polymer 3d printers came on the scene in the 1980’s. The number of technologies that now fall under the 3d Printing (or AM) umbrella and the quality of these is constantly increasing, as is the opportunity to use 3d printing for production components too.

olymer 3d printing is now regularly used to create robust engineering solutions for aerospace, automation, automotive, medical, and many other industries. Industrial-grade machines using laser sintering to additively manufacture components are among the most common used for serial production of AM parts. The beauty of this technology (laser sintering) is the absent need for support structures and the subsequent minimal requirement for post processing and finishing of parts. The result is a greater surface finish and part quality direct from the build process. The automotive industry is making large transitions in exploiting additive manufacturing and all the benefits it has to offer, with many car manufacturers making huge investments to bring the technology in house to develop and produce parts faster. Due to the fact there is zero tooling needed for 3d printing, the inherent design freedom allows for rapid iteration of prototypes as well as smaller batch production, without the high cost of moulding on in applications where the number of vehicles being produced is lower - examples of this being supercars, hypercars and race cars (Formula 1 etc.).

There are also many other instances where 3D printing can be used to improve a design and reduce its complexity for manufacture. For example, in robotic grippers where the ability to integrate complex channels alongside fixture areas and touch points for the objects to be picked reduces the need for assembly and complex machining strategies. This means that channels can be designed for functionality rather than machinability. Moving parts and part marking can also be built in to designs to reduce the need for further assembly or etching/tampography once a part has been manufactured.

Manufacturing PDATE

With the technology and materials now on offer, polymer 3D printing opens many doors to companies looking for solutions to complex design needs, tighter lead times, and cost reduction. AM is now an appropriate solution for serial production challenges that other technologies present and further machine and material developments will continue to disrupt conventional manufacturing as time goes on. Prototal UK, based in Newbury, have been 3D printing polymer parts and helping customers to exploit the benefits of the technology in a high number of applications for over 20 years. For more information visit www.prototaluk.com Written by: Victoria May, Sales & Marketing Manager at Prototal UK

November 2021

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

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interroll.com

5 Tech Trends Dominating the Manufacturing Industry

The manufacturing industry is an important piece of the global economy. It provides products and services that keep people alive and well. With such a significant impact on society, it is important to stay informed about top IT trends in the manufacturing industry. The best way for any manufacturer to stay ahead of their competition is by embracing innovation. Anyone caught standing still or letting their business regress is at risk of falling behind everyone else. To make sure you’re ahead of the curve, think about implementing some of these tech trends currently dominating the manufacturing industry.

What are the current trends in manufacturing?

Manufacturing PDATE

Predictive Analytics No-one can know the future but with predictive analytics, we can get pretty close. Predicting when machines need maintenance or when outages might occur boosts efficiency and better decision-making. This is a move away from reactive maintenance. Don’t wait until a machine needs to be repaired to carry out fixes. Use predictive analytics to identify a machine’s future problems and act accordingly. This improved way of managing maintenance is good for manufacturers.

November 2021

What’s even better is the impact predictive analytics has on operational efficiency. Imagine the relevant people instantly receiving a notification when a certain line is consuming more energy or raw goods than usual. Or, being able to highlight optimal batches and spot behaviour through machine learning, rather than hoping that a pattern is identified and understood by a human. The same concept applies to decisionmaking. Business decisions should be based on real-time data, not gut instinct. Predictive analytics isn’t a passing trend, it’s an absolute necessity. Not every business is currently set up to work in this way but it’ll soon be the norm for everyone. The Connected Worker Being able to connect workers in the plant with those back in the control room saves time, energy and resources. For this to be a reality, both parties need to be able to access the same information to be able to carry out their work. This connectivity can be achieved through digital business process capture, forms and workflow capabilities. It’s about accessing the same data but augmenting it to suit

the device and needs of the users. Augmented reality (AR) is just one route that’s leading businesses towards the connected worker. Pokémon Go is probably the most famous use of AR to date. Its huge success showed that the technology works, not just for catching Pokémon but also practically within the manufacturing industry. Imagine an engineer sent to diagnose a fault with a machine. AR allows the engineer to hold up a tablet over the machine and receive valuable insight about what’s going on beneath the surface. To correctly identify the issue and find a fix, they need all of the associated essential information. AR ensures the plant floor worker receives the same data as those back in the control room, although it’s augmented in ways to suit their specific needs. It might be that they need assistance from a colleague after identifying the problem. Connected worker technology enables another engineer to dial in remotely so that the two can discuss possible solutions. Issues are dealt with in a much faster way thanks to AR and the link it enables between systems. Read more here

Reduce unscheduled shut downs, reduce maintenance costs and improve plant safety with our Valvescan Diagnostic Monitoring System. Our revolutionary system is an end-to-end solution that captures data from every valve operation, analyses it and provides targeted alerts on the valve health without any requirement for involvement from plant personnel or any potential impact on the asset real-time control integrity. It is a true IIoT solution for automated valves. This system is not only a pioneering development in valve monitoring, it is also; ● Cost effective and easy to install ● Works with all existing valve systems ● Enables data retrieval and transmission to the cloud ● Provides a ‘real time health’ check on the valve and alerts when performance drop off is detected

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