Manufacturing & Engineering Production Magazine - July/August 2022 by Lapthorn Media

MANUFACTURING PRODUCTION

AUTOMATION

NO BUSINESS IS TOO SMALL FOR AUTOMATION - BY DR PAUL RIVERS

MANUFACTURING

PRODUCTION

JULY/AUGUST 2022

IMHX 2022

6th – 8th SEPTEMBER NEC, BIRMINGHAM

ENGINEERING

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CONTENTS 12 39 10 Editor

Paul Attwood editor@mpemagazine.co.uk

Senior Editorial Assistant Francesca Amato editorial@mpemagazine.co.uk

16 10 12 16 39 50

No Business is Too Small for Automation, by Dr Paul Rivers ‘Repair not produce’ with automated Chiron Additive Solution Siemens Congleton on track to hit carbon neutral target in 2022 - eight years ahead of goal Alok Sharma MP officially opens Tower Cold Chain’s global HQ Siemens’ automation and measurement technology keeps Plastic Energy’s plants recycling

Features Editor

Harry Peters editorial@mpemagazine.co.uk

Production/Design

Laura Whitehead laura@lapthornmedia.co.uk

Sales Manager

Charlotte Chapman charlotte@mpemagazine.co.uk

Sales Executive

Felicity Hamilton sales@mpemagazine.co.uk

Accounts

Richard Lapthorn accounts@mpemagazine.co.uk

Circulation Manager

Leo Phillips subs@mpemagazine.co.uk

Publishing Director

Editors Note It has been truly amazing to see Exhibitions and Industry events taking place, it has been a busy few months! We are looking forward to the upcoming IMHX 2022 Show, taking place in September. In this edition of Manufacturing & Production Engineering Magazine we hear from Dr Paul Rivers, Managing Director of Guidance Automation. He discusses the importance of embracing automation with an approach that best suits individual business needs, no matter how big or small the business may be. Additionally, Craig Whitehouse, Managing director of Invar Integrations, gives us an insight into problem solving within the warehouse, discussing how bringing a combination of technologies along with the skills of an integrator can successfully tailor solutions for optimum performance. We hope you enjoy this issue and as always, if you have any news that you would like to feature within the next edition please email details to editor@mpemagazine.co.uk

Paul Attwood Editor

Maria Lapthorn maria@lapthornmedia.co.uk

Lapthorn Media Ltd

5-7 Ozengell Place, Eurokent Business Park, Ramsgate, Kent, CT12 6PB Tel: 01843 808 117

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Company News

Robotics specialist targets global growth with immersive technology investment A Cumbrian engineering firm, supported by Made Smarter, is using immersive technologies to drive global growth and innovation, and create new highly skilled jobs. Forth Engineering, based in Flimby, specialises in the manufacture of bespoke robotics that can be used in harsh environments for nuclear, oil and gas, marine, and renewables sectors. With the support of Made Smarter’s North West adoption programme, Forth is investing in a hardware and software solution which will allow its client to step into a virtual room and interrogate a 3D model of their asset from anywhere in the world. They are adapting office space to create a mixed reality studio and will use a leading Extended Reality (XR) headset and mixed reality smart glasses to enable customer demonstrations. The use of digitalisation, immersion, and presentation technologies will allow Forth to deliver innovative and novel solutions to complex problems globally, opening up new markets and increasing services offered to customers. Moreover, the team of 38 staff believe the value-added service will give it a competitive advantage as it is forecast to increase GVA by at least £500,000 over

the next three years and in the process create five new, highly skilled jobs. The solution works by converting 3D data of assets into a model using 3D visualisation software. This will allow the asset to be viewed within virtual/mixed reality environments in a true to life scale. Forth will then use a leading Extended Reality (XR) headset to project a clear and precise visual representation of the asset into a room at their facility. Meanwhile,

Oxford Flow grows workforce by 80% and eyes global expansion Oxford Flow, the flow control equipment specialist for energy,

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water, and industrial process industries, today celebrates impressive headcount growth of 80% over the last 18 months as the company eyes international expansion across EMEA, India and the Americas. The company, which currently works in the USA, UK, the Middle East and APAC, has invested heavily in both workforce development and product R&D to build out award winning, innovative product and service lines to support gas distribution, oil and gas and power generation industries worldwide. Oxford Flow has made several senior appointments to build out its growing management team, including John Kett as Head of Field Operations, Tim Doole as Head of Engineering and Rob Green as Operational Development Manager. Tim Doole offers more than 15 years’ experience in hi-tech emergent industries such as aerospace and

mixed reality smart glasses are sent to the customer to access a virtual face to face meeting or inspection scenario from the safety and comfort of their own office. What is more, the smart glasses will create a hologram of the customer in the studio where they can interact and interrogate the asset, which can be animated and exploded into parts. For more information, visit www.madesmarter.uk

automotive and John Kett, brings three decades of engineering and valve industry experience, having previously worked for Severn Valve Solutions and Tyco Valves & Control UK. Similarly, Rob Green offers more than 40 years’ experience in the valve production industry having spent a substantial part of his career as Operations Director as Severn Glocon, with a significant focus on both the UK and Indian supply chains. Oxford Flow recently announced the launch of its IM-S and IM-C valves, which are adaptions of its original IM series gas pressure regulator. These latest iterations have been designed to be more compact and can be retrofitted into gas networks around the world, offering a hydrogen-ready solution for energy transition, ensuring the future security of gas network systems globally. Oxford Flow now has operations across the US, Europe, and Asia Pacific with offices in Houston and Oxford. The company employs people globally across its engineering, sales, operations and safety functions.

Company News

VCampus – approximately 100 trainees took part in the training event ATS joins Composites UK Advanced Tooling Systems UK Ltd (ATS), one of the UK’s leading engineering service providers to the automotive, aerospace, moulding and tooling industries, has joined industry association Composites UK. With over 350 members, Composites UK acts to encourage continuous growth and development of the industry, promoting the best practice use of composites materials. As well as offering business support and strong influencing representation, the association provides an extensive series of networking opportunities for companies in the industry to share knowledge and expertise. ATS’s ability to manufacture in-house in the UK and provide sample composite overmould tooling using very specialised materials such as heavily glass-fibre loaded PEEK & PPS have been instrumental in its continuing success and growth. In recent years, the company has expanded into new industry sectors and secured many development contracts for both coupon and volume tooling for a variety of customers throughout Europe. ATS says this growth has made it the ideal time to join Composites UK. In particular, it will enable the company to engage more closely with other members, especially regarding technologies surrounding the combining of Engineering Polymers.

From 22nd until 24th June 2022, the VCampus training event for trainees from the cutting tool industry took place for the first time. The VCampus was organised by the sharpening specialists VOLLMER, who, via the Sieglinde Vollmer Foundation, is dedicated to the development of young people. Approximately 100 trainees were on-site at the company’s Biberach headquarters to gain new motivation, inspiration and knowledge through practical workshops on industry-specific topics. Furthermore, the young learners had the opportunity to form extensive networks in a relaxed atmosphere. In parallel to this, the training personnel were able to participate in workshops and exchange opportunities on the topics of training, marketing for training or Learning 4.0. A lack of skilled personnel, academisation and the war for talent are all topics that concern the tool industry across the world and it must be tackled. It was against this backdrop that the Biberach-based sharpening specialist VOLLMER set up the VCampus training event. Via the Sieglinde Vollmer Foundation, VOLLMER champions the development of young people, particularly those interested and engaged in the so-called STEM subjects (science, technology, engineering and mathematics). The approximately 100 VCampus participants are internal and external

trainees who are currently completing technical, industrial or commercial training in the tool industry. At VOLLMER, they received exclusive practical knowledge from the areas of technology and IT, right through to business studies and methodology. The young talent was able to compile their timetable from the diverse offering – to suit their job, interests, experience and previous knowledge. In the evening, VOLLMER invited the participants to joint events for networking and exchanging ideas. Learning, connecting and experiencing – These three points are the three pillars of the concept of VCampus. Furthermore, 20 external and internal training managers visited the VCampus days’ event to participate in separate workshops and to exchange ideas about day-to-day training. In total, 30 speakers shared their knowledge with the participants in over 60 workshops. “With a view to learning, networking and experience, we use the VCampus to focus on those who will shape the future of the tool industry,” says Jürgen Hauger, CEO of the VOLLMER Group. “The more than 100 years of experience that VOLLMER has collected in vocational training was poured into the training event. Concerning our Sieglinde Vollmer Foundation, we want to further strengthen our future and expect to hold the VCampus event again in two years.”

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Company News

Altus Looks Back at Ten Years of 3D SPI Innovation 3D Solder Paste Inspection (SPI) systems have been a game-changer in reliable electronics, ensuring that complex PCBAs are fail-safe. A trailblazer for this innovative inspection is Koh Young. Recently celebrating 20 years of innovation and ten years since they introduced the concept of 3D measurementbased solder paste inspection, Altus, a leading distributor of capital equipment in the UK and Ireland, looks back at how 3D SPI has revolutionized the inspection industry. Joe Booth, Altus CEO, said: “During the last ten years, we have seen an increase in manufacturers investing in 3D SPI systems. As technology has advanced and electronics have become more complex, the value of the 3D measurement data has increased. The data not only helps to ensure high quality print processes and production results, but it also improves reliability, quality and performance of the PCBA. Investment in 3D SPI is no longer an optional extra but a necessity on any SMT line.”

During the last ten years, we have seen an increase in manufacturers investing in 3D SPI systems. As technology has advanced and electronics have become more complex, the value of the 3D measurement data has increased.

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Since the Koh Young systems use light measurement, they produce the most accurate measurements of a PCBA; therefore it can be used to set the tightest tolerances. This results in better quality inspection, PCBA quality and a large reduction in false calls. Thanks to this intelligent automated technology which has the highest level of connectivity for all the inspection stations, overall automation capability is enhanced. “Smart customers know that investing in an SPI often leads to the highest return on investment of any inspection or test process in production,” said Joe Booth. “They know this because it offers the earliest opportunity to ensure that solder paste performance is optimised and any failures are caught early before the cost of correcting those errors significantly increases. “It is widely accepted that 70-80% of SMT production errors are linked to solder paste and, so controlling that aspect of a line has always and will remain a priority. “SPI is where Koh Young began full 3D metrology, and now, one of every two SPIs sold globally is a Koh Young platform. This market dominance is reflected in the UK and Ireland by the consistent sales performance over the years, and the saturation effect we see with many sites utilising both Koh Young SPI and AOI on all their production lines.” Koh Young offers a range of 3D SPI systems to fit any SMT line including KY8030–3, the industry’s fastest true 3D SPI solution with integrated auto-repair dispenser, and aSPIre 3 with a world-best performance that is suitable for a variety of production environments. To find out more about Koh Young’s 3D SPI solution contact Altus Group www.altusgroup.co.uk.

Thorite becomes first UK premier partner for Norgren Valve Islands Move will reduce order turn-round to just 72 hours. Thorite has become the first UK company to be named a Norgren Premier Partner, enabling it to construct and distribute the worldleading valve islands from its Bradford headquarters. The contract to build bespoke valve islands in-house means Thorite can reduce delivery times from roughly three weeks to just 72 hours from receipt of an order. Thorite, the UK’s leading independent supplier of air and fluid power products, has a 60-plus year partnership with Norgren, a global leader in fluid and motion control technologies. It has invested £15,000 in testing facilities and stockholding at its Bradford headquarters to ensure it meets the same quality standards that Norgren are known for. The recently launched webstore now features an interactive valve island configurator, allowing customers to specify their own bespoke manifold and send it immediately through to the system division for quoting and production using the company’s comprehensive stock of Norgren components. Norgren is a US-based company with manufacturing plants around the world and a sales and service network in 75 countries. It has UK bases in Lichfield and Manchester, as well as manufacturing plants in Bristol, Leeds and Poole. The Norgren valve island contract marks another milestone partnership for Thorite, which recently became the first UK industrial supplier for Sheffield-based GWE’s Eco-Max voltage optimisers.

Automation Made Smarter survey reveals need for manufacturers to digitalise to survive, recover and grow

3D scanner robot investment means Danfoss Power Solutions can measure component dimensions to micron level Danfoss Power Solutions, a leading global supplier of mobile and industrial hydraulics as well as electric powertrain systems, has invested in an advanced 3D scanner robot for its joystick manufacturing lines in Nordborg, Denmark. The new device is boosting inspection routines by measuring component dimensions to micron-level precision, providing customers with even higher product quality. Danfoss Power Solutions’ Nordborg facility manufactures thousands of joystick variants for off-highway vehicles, such as forestry machines, harvesters, cranes, tractors and more. With the new 3D scanner robot, operators can tell immediately if a joystick component is within specifications. This capability has eliminated the need to outsource time-critical metrology requirements to a third-party coordinate measuring machine technology provider. The investment is thus saving considerable time and providing greater in-house control over the manufacturing process. Abel Dukai, mechanical engineer in the company’s Connect & Controls Solutions business unit in Nordborg, is leading the 3D scanner project alongside his colleague, production technician Grzegorz Leonhard. “The scanner is so fast and easy

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to use that we can literally verify component dimensions while we manufacture, which is not possible with CMM technology,” states Dukai. “We now know immediately whether part dimensions are 100% identical to the computer-generated design files, so the 3D scanner has taken our quality testing capability to a new level.” Dukai adds that he was not dissatisfied with the third-party metrology specialist and will continue to use the company for tasks where speed is less critical. The innovative GOM 3D scanner robot uses narrow-band blue light to measure up to 12 million points on the component surface within a few seconds, subsequently creating a 3D image. Colleagues at Danfoss Power Solutions then compare this image to the original CAD file. According to Leonhard, the scanner offers micron-level precision, down to 0.007 millimeters. “We are talking extreme accuracy,” he says. “And it can even scan highly complex shapes and forms. It’s incredible technology that’s already gaining prevalence in the automotive industry. I’m glad we now have it on board, too.” Visit the Danfoss joysticks webpage to learn more about the products benefitting from 3D scanning technology.

Manufacturers are being urged to accelerate technology adoption to adjust to the economic challenges around the supply chain, energy costs, post-Brexit and COVID. Made Smarter, the movement connecting UK manufacturing industries to digital tools, conducted a survey of some 200 SME manufacturers in the North West. The results highlighted how the last two years affected them, and their approach to digitalisation and their priorities going forward. The survey revealed while many (35%) makers, particularly smaller businesses, are focussed on survival after a turbulent few years, achieving growth by improving productivity and adopting digital technologies are key drivers for SMEs. In fact, two-in-five manufacturers (38%) revealed they had plans to invest in or adopt new technology in the next two or three years. Meanwhile, one in three respondents said their latest business strategy included integrating digital technology or a roadmap towards automation. The survey also showed that manufacturing leaders are exploring a range of technologies to revolutionise the way they make and distribute their products. Almost half (44%) expressed an interest in data and systems integration technologies, while two-thirds were considering industrial machinery, robotics and automation. The survey also tapped into attitudes towards technology adoption where it found almost a third (29%) cited productivity, efficiency, and output as key drivers for manufacturers in 2022 and beyond, despite the current business climate. Increasing revenue (18%) was the secondary motivator to invest in new digital tools, followed by attracting and winning new customers (17%). However, while the majority (80%) of manufacturing leaders expressed a clear understanding of what they need to do and the benefits of investing in new technologies, once they are aware of the benefits, barriers to adoption remain. Two in five (42%) manufacturers said that the lack of capital and funding to invest was holding them back from investing, as well as the lack of time (10%).

Automation

Made Smarter was designed to overcome these and other hurdles by helping SME manufacturers navigate through complex technology advice and decisions.

The survey also revealed a fragmented awareness of the business advice and support available, meaning SMEs are potentially missing out on valuable funding and support available to them. Made Smarter was designed to overcome these and other hurdles by helping SME manufacturers navigate through complex

technology advice and decisions. Initial registration only takes five minutes and is followed up with a digital transformation workshop to identify core challenges, provide a bespoke digital manufacturing roadmap, and pinpoint other ways that Made Smarter can support a maker’s digitalisation. For more information, visit www.madesmarter.uk

Manufacturing & Production Engineering Magazine

Automation

No Business is Too Small for Automation By Dr Paul Rivers, Managing Director of Guidance Automation There remain many misconceptions around implementing automation. Guidance Automation’s recent research identified the greatest perceived barriers to be the costs involved / budget constraints (76%), the need to up-skill staff (74%), and the belief that warehouse processes are too changeable (63%). But a further widespread myth is that a business may be ‘too small’ for automation. This is emphatically not the case. As Dr Paul Rivers, Managing Director of Guidance Automation explains, small and medium-sized enterprises (SMEs) shouldn’t be left behind, and instead, can level the playing field by embracing automation with an approach that best suits their business needs.

The SME Market SMEs are the backbone of Europe’s economy, representing 99% of businesses in the EU and employing over 100 million people. Specifically in the UK manufacturing sector, there are over 130,000 SMEs who are all leading the way in innovation – with research highlighting that SME manufacturing output grew at the fastest pace on record in the three months to July 2021. However, both SMEs and larger organisations continue to face the same logistical challenges – from increasing material and labour costs, to a shortage of skilled resources. And particularly for SMEs, it can be more challenging to attract workers – especially while the country faces a large skills gap within

manufacturing. Yet, these hurdles can, to an extent, be overcome by beginning to embrace automation – whether it is through a gradual or flexible approach, such as implementing one or two robots or renting autonomous vehicles – allowing SMEs to start to reap the benefits without overhauling existing processes. Additionally, SMEs have the upper hand. With agility and flexibility on their side, SMEs can capitalise on their ability to pivot quickly and make decisions, such as deploying innovative technologies, without having to go through as many hierarchical levels for sign-off. Therefore, the key question remains – what is stopping them from leveraging the benefits of automation?

Embracing Automation Automation is transforming industries around the globe – yet in the SME market, 57% of manufacturing leaders feel that they aren’t confident with technology, and are falling behind in terms of digital adoption. Despite hesitancy, the use of automation in the warehouse holds great potential for SMEs – including improved labour allocation, enhanced productivity and reduced errors. With the right technology in the right place, SMEs can automate mundane tasks – releasing the workforce to be upskilled and take on more advanced, value-added jobs and better manage process changes as they arise. For example, taking a collaborative and cost-effective approach, one or two robots can be added to any size manufacturing business without the need for disruption, while delivering business improvements – reallocating staff to more profitable areas and allowing the robot to undertake the repetitive labour. This is particularly beneficial for the small-tomedium business market to improve job satisfaction, and in turn, labour retention.

Test Before You Buy While different levels of automation exist, today’s smaller businesses may not necessarily understand how automation could benefit their organisations, as 62% of respondents to the Guidance Automation research indicated, or how it can fit into existing processes. The survey also found that 58% of respondents believed that the nature of change when embracing automation would be both sudden and rapid. But there is no need

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Automation to ‘rip and replace’ existing processes, which can result in significant business disruption. Instead, SMEs can realise the benefits of automation with a gradual or flexible approach. Firstly, it is key to identify the right opportunities for automation, which can deliver immediate gains. To begin this process, SMEs should partner with an automation expert to undertake an assessment of their current warehouse or production facility in order to assess and advise on the viability of the project. An expert will be able to identify possibilities of where automation can be added, and the benefits and efficiencies that can be gained. Once the most appropriate processes and matching technology have been identified, a logical next step is to consider a trial period, allowing staff to go through a ‘learning phase’ of working alongside the technology, while also demonstrating the benefits; from improved operational speed or increased efficiency. By ‘trying before you buy,’ SMEs can realise how easy and intuitive the automation process can be; how they can improve their operations; as well as

how and where automation and humans can work together. While reducing barriers to implementation, flexible (e.g. opex as well as capex) and gradual approaches to automation also enable SMEs to be able to cope with any fluctuation in the business, particularly during busy or peak seasons. This approach removes the need for investments in expensive and fixed infrastructure, and alternatively, businesses can add more robots or

Automation is transforming industries around the globe – yet in the SME market, 57% of manufacturing leaders feel that they aren’t confident with technology, and are falling behind in terms of digital adoption.

‘cobots’ (collaborative robots) as they require, removing the need for seasonal staff, while meeting demand. This comes in line with results from Guidance Automation’s recent research, as both low operation costs (35%) and increased productivity (31%) were identified as the most desired benefits of using Autonomous Mobile Robots (AMRs). With the ability to start small and scale up, automation is achievable with minimal disruption and upheaval.

Conclusion The cost and disruption of automation has previously made implementing new technology a challenge for manufacturing SMEs. But as robots and AMRs continue to become more accessible and costeffective, small-to-medium businesses should consider the long-term benefits of investing in automation. By partnering with an automation expert and undergoing a small-scale trial, SMEs can understand how automation can be embedded in any organisation, of any size, to create an efficient and flexible working environment – that can also help them to remain competitive against their larger counterparts.

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Manufacturing & Production Engineering Magazine

Automation

‘Repair not produce’ with automated Chiron Additive Solution In terms of economic and ecological sustainability, the call to repair rather than produce new is correct and forward-looking. When it comes to repairing moulds and other components instead of producing new ones, laser metal deposition (LMD) is a proven key technology - with a growing potential for new areas of application. At the recent ‘reFORM’ workshop, which was part of the CHIRON Group’s 2022 Open House event - the automation of LMD repair processes took centre stage. This groundbreaking technology is now available in the UK from the Engineering Technology Group (ETG), and for manufacturers that implement it, they can save time, costs and act extremely sustainably.

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Automated welding on the AM Cube meets our quality requirements and increases service life by a factor of 2.5 to 3. Dominik Hipp, Head of Toolmaking at Hammerwerk Fridingen GmbH

It’s actually like machining, only LMD works the other way around. Instead of removing material, it is applied. Using powder or wire, or both in combination. What is feed and depth of cut for one is deposit rate and layer thickness for the other. Where one cools his workpiece, the other heats it. Either way, the component has to be produced with the required quality and cost-effectiveness with the additional criteria of being energyefficient and resource-saving.

LMD process technology – automated repairs LMD was represented at the CHIRON Group’s ‘reFORM’ workshop in Tuttlingen where Cedric Bardenhagen, Key Account Manager at Siemens AG, gave a very

Automation clear picture of the motivation to face this challenge in his lecture. He discussed a newly produced gear wheel with a diameter of 500mm and a weight of 230kg that requires almost 2,000kW /h throughout its production chain. That’s 90% of the energy for steel production and forging the mould, and the remaining 10% for machining and post-processing. In comparison, a gear wheel made from recycled steel uses ‘only’ 39% of the manufacturing energy. If you now repair such a wheel with an automated LMD process, you only need 17% of the energy of a new wheel, or 42% of a recycled one, to get a wind turbine running with these components. In short, repairing with additive manufacturing is highly positive for climate balance.

Materials and welding - that’s science Heat-resistant chrome steels are generally used for moulds and tools. The stresses to which a forming tool is subjected can vary greatly. Whether it’s a forging tool for the production of a generator shaft with a dead weight of 250 tons or a cone roller for the production of

seamless rings, the loads that occur are fundamentally different. This was impressively demonstrated by Dr. Michael Nolde, a member of the management of Capilla Schweissinstrumente GmbH, using the example of a fully automated forging plant from the forging blank to the finished part. To make mould and tool more wear-resistant, various welding processes and protective layers of iron, cobalt or nickel alloys are applied. What is important when manufacturing new tools, but also when repairing them is the breakouts and worn punching surfaces. In terms of material and process technology, it is a science in itself. However, this is the only way to achieve a good form and tool quality with long service life as the result. At best, these even surpass those of unwelded new dies. This finding represents indispensable knowledge for the successful implementation of automated LMD processes.

Multifunctional system for automated LMD process The CHIRON Group Additive Manufacturing team used this highly specialist knowledge of material properties in welding processes to develop the AM Cube. With today’s very large variety of materials, the flexibility of the system is an important criterion for an automated LMD process. With so many shapes and contours and so many materials used in daily practice, it makes sense that the system can be changed easily and quickly. Powder is the preferred welding material on the one hand, and wire on the other – the user has all the options. Dominik Hipp, Head of Toolmaking at Hammerwerk Fridingen GmbH, is one such user, responsible for the production of dies and tools with a daily tonnage of around 200 tons. Together with the CHIRON Group, he works on several projects, including the repair of cutting rings. “Automated welding on the AM

Cube meets our quality requirements and increases service life by a factor of 2.5 to 3,” reports Hipp in his presentation. “The decisive factor in automating the LMD repair was also the fact that there are hardly any skilled workers left for manual welding. Now that the automated process is in place, it is important to introduce employees to the automated LMD process and get them enthusiastic about it.”

Data is the be-all and end-all Till Oeschger, Project Manager AM Cube at the CHIRON Group says: “Process control and data effectiveness are a must for automated LMD solutions.” What the workshop participants recognised in the lecture was the complexity of the topic, from the physical, chemical and mechanical requirements for tools and materials to build-up welding for graded alloys. A lot of factors come together and ultimately, parameters and data must be used to construct the component to make automated LMD processes safe and reproducible. This data is valuable on several levels. With Siemens NX CAM, the machining processes can be conveniently programmed with the system and workpiece data simulated in advance with the help of the digital twin. An error-free and already optimised program can be transferred 1:1 to the system. Data also plays an important role during machining. All relevant process data is recorded via two new digital systems from the CHIRON Group. The Via DataLine AM permits all relevant process data to be continuously displayed live, recorded and documented in a compact quality report. Product and process quality can thus be reliably assessed. The VisioLine AM system visualises and saves video files that are captured by multiple camera systems. Once parameters and tolerances have been entered, they serve as a reference and in the event of deviations, you can take immediate, targeted action.

The decisive factor in automating the LMD repair was also the fact that there are hardly any skilled workers left for manual welding. Now that the automated process is in place, it is important to introduce employees to the automated LMD process and get them enthusiastic about it. Dominik Hipp, Head of Toolmaking at Hammerwerk Fridingen GmbH

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News

Siemens and Liverpool John Moores University launch new top-up degree programme Siemens has teamed up with Liverpool’s John Moores University to launch the top-up degree in Manufacturing Systems Engineering. The Bachelor of Engineering (BEng) honours degree will feature a range of academic models including two modules and a project that can be applied in the workplace. This will be further combined with Siemens-approved ‘PLC Programmer Certification’. It will be available to engineering professionals to upgrade their existing higher national certificates or diplomas HNC/HND level looking to gain new skills, experience and knowledge and study through to degree. Jason Phin, Training Solutions Business Manager at Siemens Digital Industries said: “The manufacturing sector is an industry that requires a high percentage of specialised skills and there is a need to revitalise the workforce with digital and updated technology skill set. The pandemic threw a curve ball where

The course will give the students an opportunity to put perspective on what they know practically but with a much better understanding and knowledge of theory.

it experienced a huge shortage and the need to upskill existing employees was heightened. The programme is open to anyone with a relevant HNC/HND and we will also take into account recognition of prior learning (RPL) or accreditation of prior learning (APL).” Dr Rob Darlington, Program Leader from Liverpool John Moores University said: “We have a robust engineering offering for full-time engineering students and long-standing relations with industry organisations. “However, with this partnership we are extending our reach to those that may have missed out on the full-time university experience. At the end of the one year the cohort of students will have the same degree as any other student. “The course will give the students an opportunity to put perspective on what they know practically but with a much better understanding and knowledge of theory. It’s a reverse situation where they come with industry background making the degree a holistic experience for the candidates.”

Bosworth MP returns to see Desford brick factory redevelopment progress Forterra welcomed back Member of Parliament for Bosworth, Dr Luke Evans, to its Desford site recently which is currently undergoing a £95 million expansion. Once complete, it is set to be the largest and most efficient brick facility in Europe. During the visit, Dr Evans was given a tour of the factory and shown the

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progress that has been made since the project started in 2019 and his previous visit two years ago. The new factory is being built alongside the old site in order to ensure that the latter remains operational throughout construction and in order to maintain production during the changeover. The work is expected to

Many apprentices and technical employees across SMEs and large-scale manufacturers are looking to upskill and the year-long top-up degree is a great option for them. In addition, the flexibility of the programme suits industry needs and minimises time off from work. Siemens has developed specific content, and this will be delivered through SITRAIN, a digital industry academy set up by the company to meet the industry’s skills and upskilling needs. In its two modules the course will focus on ‘Manufacturing Systems’ and ‘Industrial Management’ with 20 credits each. These fundamentals are key for building on a successful engineering career in manufacturing. According to the Employer Skills survey in 2019, the skills shortage density was highest in construction (36% the same as 2017) and manufacturing (36% up from 29% in 2017). Phin added: “As industry leaders at Siemens we have long championed the role of continued education and upskilling of employees across the manufacturing sector. We are hoping this alliance with Liverpool John Moores University will help further our drive to reduce the skills gap in the industry.” The degree, which has been created according to requirements of UK-SPEC, will accept applications in July for its first cohort in October 2022. In 2017 Siemens had successfully launched its first-degree programme with University of Salford with a degree in Control and Automation, which has seen 79 students successfully graduate.

complete later this year, at which point the projected capacity will increase by 16% to 180 million bricks per annum, enough to build 24,000 family homes. The modernised Desford site will offer a range of red and buff bricks designed to meet the demands of housebuilders. At the heart of the plant’s efficiency will be two new kilns using cuttingedge technology to reduce energy consumption and emissions. Dr Evans said: “I first visited Forterra’s Desford site about 18 months ago and I’m pleased to see how well construction on the facility has come since then. They have put a phenomenal amount of money into the Desford site and the project has brought lots of highskilled jobs to our area. I also talked to Forterra about the work they are doing

News MGP delivers business support plea after passing 10,000 jobs milestone A business support programme that has created and safeguarded over 10,000 manufacturing jobs is urging local authorities to ensure assistance is still in place under the new funding landscape. Bosses at the Manufacturing Growth Programme (MGP), which provides grants and dedicated consultancy to SME manufacturers in 18 LEP regions, are warning that the potential gap between European Regional Development Funding and the UK Shared Prosperity Fund (UKSPF) could see businesses left without the assistance they need. Regional Director Dean Barnes believes the fragmented nature of UKSPF – where each local district will receive its own pot of money – means it will be difficult to deliver good quality

support to management teams that have guided their firms through Brexit and, more recently, Covid-19. The rallying call comes as MGP reveals its latest performance data, with more than £13.5million in grants delivered to 4300 companies over the last three years. This has leveraged £21m of private sector investment and helped manufacturers enter new markets, diversify their products/services, improve efficiencies and secure vital quality accreditations. “We’re about to enter one of the most exciting, but challenging times in business support where the focus will fall away from ERDF and into a new landscape where each place (it could be as small as a District Council) will be given control of what they want to invest in and how they want to shape their local investment plan,” explained Dean. “It is key that neighbouring councils work together to pool funding to deliver support at a regional level to ensure they get the most out of their budgets and reduce the amount of ‘business support’ noise in the marketplace.” He went on to add: “The UK Shared Prosperity Fund is intended to help the Government’s desire to ‘level up’, but businesses must have a voice on what they want. They don’t just need grant funding, they also want advice, best practice implementation and help with long-term improvements.” Funded by the European Regional Development Fund (ERDF) and delivered by Oxford Innovation Advice, MGP was launched in 2016 to create a targeted service to support manufacturing SMEs. This focused on creating a team

of Manufacturing Growth Managers who work with management teams on initially completing strategic business reviews. From there, they provide grant funding and signposting services to specialists that deliver improvement projects in strategic planning, productivity and process improvement, competitiveness, innovation and leadership and management. Nearly a third of firms so far have chosen to tap into marketing and market knowledge support, followed by a quarter choosing help to improve productivity and 14% wanting assistance with continuous improvement. Jane Galsworthy, Managing Director of Oxford Innovation Advice, commented: “We are already helping with the ‘levelling up agenda’ by supporting small businesses in less developed areas to grow and have adapted our support model to meet evolving business needs. “These include continuing to boost productivity, helping firms work towards Net Zero, job creation, internationalisation and, increasingly, embracing digitalisation and Industry 4.0.” She concluded: “There has been some massive strides forward in business support and we’ve seen first-hand how the right expertise can unlock the potential of some of our brightest SMEs. It would be foolish to throw that all away with the launch of UKSPF funding!” For further information, please visit www. manufacturinggrowthprogramme. co.uk or www. oxfordinnovationadvice.co.uk.

to ‘plug the skills gap’ and encourage people from our area onto apprenticeships and training programmes so they can enter into highly paid jobs having learned valuable skills for the future.” Stephen Harrison, Chief Executive at Forterra said “We were delighted to welcome Dr Evans back to see the progress made here at Desford over the past two years As one of Britain’s largest manufacturers of building products, we endeavour to set the benchmark in terms of manufacturing efficiency, output and sustainability. Our new facility will allow us to respond to our customers’ increasing demand for products as the rate of housebuilding continues to accelerate nationwide.” For more information on Forterra’s Desford plant visit: https://www. forterra.co.uk/about-us/manufacturingdevelopments/

Manufacturing & Production Engineering Magazine

Drives & Controls

Siemens Congleton on track to hit carbon neutral target in 2022 - eight years ahead of goal Partnership between Siemens Digital Industries and Smart Infrastructure businesses accelerates factory towards net zero

Siemens believes that sustainability is a force for good and can deliver value for all its stakeholders.

Siemens’ Congleton factory is on track to achieve carbon neutrality this year eight years ahead of its original target. The operation, which manufactures more than 1.2m controls and drives each year, is inching its way to the major milestone after deploying a range of sustainable solutions for energy generation and demand with support from Siemens’ energy and performance services business, Smart Infrastructure.

Andrew Peters

These include generating 75kw of renewable energy through a hydro-electric plant at Havannah Weir on the river Dane and using carbon neutral, certified biogas to power its on-site gas engine. These measures alone saved over £250,000 pounds a year and took the 80% powerindependent factory off the grid. Beyond these innovations, Siemens Congleton adopted a building management system which automatically adjusts to drive energy efficiency improvements, while modern windows and LED lighting have reduced the total energy bill by 13% and 30% respectively. Combined with reducing waste to landfill to zero and EV charging for staff and visitors, the Cheshire site is eight years ahead of Siemens’ original 2015 commitment to ensure carbon neutral operations by 2030.

In the UK Siemens’ progress has been recognised by The Carbon Trust, an expert partner for supporting organisations to achieve science-based targets. In June it awarded Siemens its Route to Net Zero Standard tier one certification for ‘Taking Action’. Commenting on the achievement, Andrew Peters, Managing Director of Siemens Digital Industries Congleton, said: “Siemens believes that sustainability is a force for good and can deliver value for all its stakeholders. We want to help customers achieve sustainable growth and to transform their industries through decarbonisation. The first step of that is for us to achieve these ambitions in our own operations.”

Commenting on this milestone achievement, Olivia Whitlam, Head of Sustainability, Siemens Plc said: “Siemens is taking a holistic approach to achieving net zero and we are pleased to be guided by the Carbon Trust who helps us monitor our progress each year. “We have 8,600 people spread across offices and 11 manufacturing sites across the UK and we are creating innovation up and down the country with sustainability at the core of our operations and services. Our Congleton factory is paving the way for sustainability whilst setting a great example on how manufacturers can join this amazing journey to net zero.” Congleton’s trailblazing story will be shared at Siemens’ two-day conference and exhibition, Transform 2022 at Manchester Central on July 12 and 13. The event will bring together hundreds of industry leaders, influencers and regulators from across the UK and Ireland to collaborate and solve some of the most pressing organisational challenges.

To register for Transform 2022 visit: https://new.siemens.com/ uk/en/company/fairs-events/ events/transform-2022.html

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Electrical & Electronics

Top 3 safety hazards to avoid for PV solar installations Safety levels during solar panel commissioning and installation have been strengthened substantially by the world’s first CAT III 1500 V true-RMS solar clamp meter Fluke, a global technology leader in the manufacturer of compact, professional electronic test and measurement tools and software, has today announced the top three electrical hazards to avoid when installing and maintaining PV solar installations to keep technicians safe. Renewable energy is one of the fastest growing markets in the world – in the UK, solar installations have doubled within the last year and are expected to double again by 2030. Such rapid expansion is accelerating the search for ways to reduce risks associated with commissioning and installing photovoltaic (PV) systems. The resulting demand for highly accurate hand-held devices capable of carrying out safe and reliable measurements in these applications has now been met with the introduction of the world’s first

Manufacturing & Production Engineering Magazine

CAT III 1500 V true-RMS solar clamp meter – the Fluke 393 FC. In PV applications current is “wild” and not limited by electronics, therefore choosing the correct solar testing equipment is vital if workers – and the PV system itself – are to be protected against a range of potential electrical hazards.

1. Electrocution The Fluke 393 FC helps to protect against the three main electrical hazards – shock or electrocution from energised conductors, arc faults that spark fires and arc flash that leads to explosions. Control measures and best practices that can mitigate these risks are different when working with PV to working with any other kind of energy generating resource. That’s why it’s important that

multimeters, test leads and fuses are rated for the application being worked on. Shock or electrocution from energised conductors can happen when current takes an unintended path through a human body, with lethal results from as little as 50 milliamps (mA) hitting the heart. Electrical shocks are typically caused by a faulty insulation of cables and wiring, damaged insulation of safety covers or improper grounding. The main places such conditions exist in a PV system are the combiner box, the equipment grounding conductor, the PV source and output circuit conductors.

2. Arc faults and arc flash Electrical arc faults that spark fires are high power discharges of electricity between two or more conductors, with

Electrical & Electronics overvoltage category CAT III 1500 V systems are being more widely used and CAT III and CAT IV equipment is essential for PV systems at high altitudes. Only the Fluke 393 FC True-RMS Solar Clamp Meter matches the insulation demands of such CAT III environments.

the discharge causing heat that can lead to the deterioration or even to burning of wiring insulation. PV systems are particularly vulnerable to arc faults caused by disruption in conductor continuity or by unexpected current between two conductors, often the result of a ground fault. Arc flash is a phenomenon of large-scale PV arrays that have medium-to-high voltage levels. Only since large-scale solar energy systems gave been created has arc flash become a DC issue, which is why arc flash hazard risk analysis must now be carried out on DC systems over 120 V. The issue is particularly prevalent when fault-checking in energised combiner boxes, where PV source circuits are used in parallel to increase current, or when carrying out checks on medium-to-high voltage switchgear and transformers. An arc flash happens when there’s a significant level of energy available to an arc fault in DC and AC conductors. The flash emits hot gases and radiant energy that can be around 19,500° C (or four times the temperature of the surface of the sun). The most at risk set-ups are residential inverters with input voltage up to 500 V and large-scale inverters with up to 1500 V. It’s essential to use a meter that’s rated for the relevant measurement category or CAT rating as well as the application’s voltage level. This is so the unit can cope with average voltage levels and high voltage spikes and transients that are capable of producing shocks or causing an arc flash.

3. Switching to 1500 V Most major manufacturers of inverters and solar modules are shifting from 1000 V systems to 1500 V for greater efficiency. For solar installations,

The meter is designed specifically for use by PV installation technicians and maintenance specialists who work in high voltage DC environments. The clamp can measure up to 1500 V DC, 1000 V AC, DC power and current up to 999.9 A DC or AC through the thin jaw which is ideal for the kind of cramped spaces found in combiner boxes or inverters. Other key features of the clamp, which has a threeyear warranty and is IP54 rated (making it well suited to work outdoors), include an audio polarity indicator that helps to prevent accidental mis wires by ensuring PV panels are installed correctly. Polarity functions and audible and visual polarity checks are crucial when commissioning a new site, whether at the combiner box level or inverter level. With a DC polarity check, it’s easy to spot if polarity of strings has been reversed accidentally, avoiding the risk of fires at the combiner box as well as damage to the equipment and danger to personnel.

Safe, reliable and rugged All test results are logged and reported via the Fluke Connect software that comes with the Fluke 393 FC trueRMS Solar Clamp Meter. Using just a phone, engineers can make and save measurements quickly, with the phone recording for 10 minutes and reporting readings to colleagues.

Safety is essential when commissioning and installing PV systems. The future of power needs tools that are able to keep you safe in harsh environments – risk is not an option and you literally have to trust your meter with your life. Hans-Dieter Schuessele

Capable of measuring and recording up to two weeks, this safe, reliable and rugged meter also comes with an 18-inch iFlex flexible current probe for extended AC current measurements up to 2500 amps. Test leads are also rated to CAT III 1500 V DC. Hans-Dieter Schuessele, Application and Technology Expert EMEA, Fluke said: “Safety is essential when commissioning and installing PV systems. The future of power needs tools that are able to keep you safe in harsh environments – risk is not an option and you literally have to trust your meter with your life. “That’s why the world’s first CAT III 1500 V true-RMS clamp meter has been designed to deliver enhanced protection for users in challenging CAT III environments. “It’s very important that there’s a solid meter with multiple functions capable of operating at that rating – the solar industry desperately needs a solution like the Fluke 393 FC.”

For more information about the new clamp meter, go to: https:// www.fluke.com/en-gb/product/ electrical-testing/clampmeters/fluke-393-fc-cat-iii1500-v-true-rms-clamp-meter

Manufacturing & Production Engineering Magazine

Fluid Handling

Three years on: HydraCell® pumps save 21,000t of polymer and over $¼million in maintenance Wanner International is celebrating the third anniversary of installing 15 Hydra-Cell polymer injection API674 pumps to an oil and gas company in India - saving 21,000

tonnes of polymer and maintenance costs of over $ ¼million across their oil fields. The only maintenance required was the recommended oil changes. The pumps were installed in 10 days in June 2019 after a successful pilot. The multi-national company is using them for alkali surfactant polymer (ASP) injection for enhanced oil recovery (EOR). Each day, 1120m3 of ASP slug is injected through 14 injector wells via two injection manifolds installed within the oil field. This equates to 80 m3 of ASP per day, per well. Each injection manifold has seven injection

lines, with each line using an individual reciprocating pump for injection. The ASP slug is prepared by mixing 2.5 weight % soda ash, 0.25 % surfactant and 1500 ppm polymer in water, and is stirred using an inline mixer before injection. Because of Hydra-Cell’s very low-shear pumping action, polymer consumption is reduced by up to 15%. Hydra-Cell’s unique valve design enables the low-shear pumping action, minimising the polymer shear, and optimising the polymer usage. With no dynamic seals, its seal-less design ensures the polymer is 100% contained, with no leakage there is no waste and keeps it free from oxygen to stop degradation. These pumps are known to run for 15+ years in other applications. They are very simple to service, with no special tools required for “in-field” inspection of diaphragms and to check valve assemblies. Hydra-Cells can run dry indefinitely and are self-priming. They are highly efficient, with more than 90% energy delivery from pump shaft to hydraulic power, achieving significant energy savings.

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Latest Product Launches

Secure fixation of irregular shaped workpieces With the fractal vice “FracVise”, the German fixturing specialist Witte Barskamp opens up new possibilities for fixing irregularly shaped workpieces. The precision vice has multi-part clamping jaws and rotating elements that automatically adapt to workpiece contours “from small to large” when clamped. With a total of 16 contact points at the smallest fractal jaw clamp level, FracVise is able to adapt to particularly complicated silhouettes and to fix them gently. In addition to the conventional “horizontal” orientated clamping method the specially designed jaws ensure a finely dosed, automatic pull-down of the part. As a result, FracVise displays an ideal, workpiece-specific combination of fit and force fixation. A jaw height of 25 millimeters and a clamping width of 0 to 92 millimeters allows room for larger workpieces. In terms of manufacturing technology, the new product is based on the modular ALUFIX fixturing system from Witte. Its all-round finely machined components made of high-strength or medium-strength aluminum thus adhere to the well-known ALUFIX precision, while an all-round anodized coating ensures the best wear resistance. Various mounting holes on the underside allow easy assembly of the fractal vise with screw or quick connections.

Manufacturing & Production Engineering Magazine

New 8-bit MCU Development Board Connects to 5G LTE-M Narrowband-IoT Networks The AVR-IoT Cellular Mini Development Board is the latest to join Microchip’s AVR® family, providing developers an easy blueprint for building IoT devices. IoT network developers are looking for an easy path to implement a secure cellular connection in their design applications but are faced with design complexities and high deployment costs. To offer a solution for network designers who need the ultimate in location flexibility, low-power consumption and deployment simplicity, Microchip Technology Inc. announces the AVR-IoT Cellular Mini Development Board based on the AVR128DB48 8-bit microcontroller (MCU). This solution provides a robust platform to start building sensor and actuator nodes on 5G narrowband IoT networks. The AVR-IoT Cellular Mini Development Board is a small form factor board making it an ideal solution for developers who want to connect IoT devices to an available 5G network. This is an essential feature for devices on the go or located in remote areas with limited availability of Long Range (LoRa®) networks or other Low Power Wide Area Network (LPWAN) solutions. Customers can tap into the flexibility and ease of design offered in the latest AVR128DB48 8-bit MCU family, including security protection

with Microchip’s ATECC608 CryptoAuthentication™ device. The ATECC608 device can easily be configured to most major cloud service providers through Microchip’s IoT Provisioning Tool. The AVR-IoT Cellular Mini Development Board comes preconfigured to send data from on-board light and temperature sensors to the cloud, viewable using Microchip’s sandbox portal. The sandbox portal provides customers with the ability to track and monitor their device in real time from a remote location. This functionality covers the core requirements of many applications in various industries including agriculture, industrial and energy, as well as consumer spaces such as transportation of goods, alarm systems, building automation and remote monitoring. The AVR-IoT Cellular Mini Development Board is a great solution for makers and hobbyists as it fits the Adafruit Feather form factor. It features a Qwiic/Stemma I2C connector for easy functionality extension, creating a clear path to production. It is also Arduino®-compatible and is supported by Microchip’s Github Library which provides functionality for HTTPS, MQ Telemetry Transport (MQTT), low power and more.

Health & Safety

Lack of Skilled Lift Truck Instructors Poses Possible Safety Risks The warehousing and logistics industry is facing a shortage of qualified Lift Truck Instructors which could lead to safety issues in forklift operations, says RTITB. “The lack of lift truck operators and warehouse staff is a frequently discussed problem. However, many in the industry are overlooking the significant Instructor skills shortage,” says Laura Nelson, Managing Director for RTITB, accrediting body for workplace transport training. “These two issues are connected. Without enough dedicated, qualified Instructors it will be impossible to fill the skills gap.” In 2020, during the Covid-19 pandemic, 50% fewer Lift Truck Instructor examinations took place compared to the previous year, creating a shortage of Instructors that the industry is still recovering from. Later, as Covid-19 restrictions around training eased, a backlog of lift truck operator training had to be addressed. The need to train operators remains high, with 9365 ‘Forklift Operator’ roles currently advertised* by organisations looking to fill these positions in May 2022. With fewer Instructors qualifying, there have been longer waits for operator training. One national logistics provider informed RTITB that current waiting times for training are approximately 10-12 weeks in certain areas for popular

machine types. Instructor courses at the same company currently have a lead time of up to 5 weeks. It is clear that the Instructor shortage is still preventing roles from being filled as quickly as needed. “Without a skilled Instructor available, there is always a risk that businesses will just ‘show the ropes’ to trainee operators. This does not prove compliance in the event of an incident. More importantly, it does not pass on the required skills and safety standards,” says Laura. “Even a highly experienced forklift operator may be sharing years of bad habits with a novice operator or could just be a terrible teacher!” “There is no substitute for practical training delivered by qualified Instructors. However, we can’t fill every Instructor vacancy overnight – solving the skills shortage will take time,” says Laura. “What we can do now to help ensure safety is to use Instructors’ time more wisely. One way is by harnessing the power of eLearning to accelerate the rate at which lift truck operators can be trained.” eTruck UK, available in the UK exclusively from RTITB, is an eLearning program providing the theory element

Even a highly experienced forklift operator may be sharing years of bad habits with a novice operator or could just be a terrible teacher! Laura Nelson

of forklift and reach truck operator training. With eTruck, it is estimated that Instructors can reduce contact training hours by 40%. The online platform enables operators to train independently online. This frees up Instructors’ time to deliver more of the practical training necessary to complete operator training. For example, without eTruck, an Instructor can train six novice counterbalance or reach truck operators in a two-week period. By using eTruck to deliver the theory element of the course, they can train up to nine novice candidates and three refresher or conversion candidates. eTruck reduces training time by two days per novice course. If adopted across the UK warehousing and logistics industry, it would result in a nationwide saving of an estimated 40,000 training days per year. “Digitalising training is an effective way to help close the skills gap faster despite facing an Instructor skills shortage. It has huge cost-saving potential, especially when considering the possible reduction in working days lost to training,” says Laura. “With online learning becoming the norm, especially for younger people, eLearning will also play a vital role in engaging trainees, helping to retain new talent for the future of the industry.”

For more information visit www.rtitb.com. *www.indeed.co.uk – 11 May 2022

Manufacturing & Production Engineering Magazine

Health & Safety

AMRs: the safe choice for the warehouse Frazer Watson, UK–Ireland Country Manager at AMR designer and manufacturer iFollow, examines how AMRs can contribute to improving safety in increasingly busy warehouses. The good news is that the UK is one of the safest countries in Europe in which to work, with consistently one of the lowest rates of fatal injuries across all industries compared to other large European economies. It’s a similar story for work related injuries and health problems. Even better news would be to continue minimising the accidents that still do occur in the warehouse. According to HSE’s ‘Transportation and Storage Statistics in Great Britain’, slips, trips or falls on the same level (45%) were the most common of the main kinds of accidents in transportation and storage for the latest three years (2018/192020/21), and 6% were from being struck by a moving vehicle. There were 10 fatal injuries in 2020/21 – a period that of course includes the Covid pandemic – which compares with the annual average number of 13 fatalities for 2016/172020/21. The fatal injury rate (0.85 per 100,000 workers) is around twice the all industry rate (0.42 per 100,000 workers). Looking at non-fatal injuries around 2.1% of workers in Transportation and Storage sustained a workplace injury. This is

moving heavy vehicles, such as forklift trucks, are travelling.

significantly higher statistically than that for workers across all industries (1.8%). Technology has always provided innovative safety solutions, but in the form of Autonomous Mobile Robots (AMRs), it can have a massive impact by changing fundamentally how work is carried out in the warehouse – particularly by removing the need for people walking in areas where fast

The pressure to fulfil orders with shorter lead times is increasing, upping the activity within warehouses and distribution centres, particularly in sectors such as grocery, which deal in large amount of fast moving items. A distribution centre typically operates with a mixed fleet of counterbalance, narrow aisle and order picking trucks rushing around it. Racking aisles are one area where these vehicles might encounter pedestrian pickers. However the busiest accident risk zones are the areas where staff manually carry or push a cart or pedestrian truck between Goods In, pick zones, packaging desks and marshalling areas. Even with careful planning of pedestrian routes, close proximity between these large machines and people – and therefore risk of accidents – is hard to avoid. All it takes is a moment of hesitation or distraction. Using AMRs to automate the transportation of goods, roll cages, pallets and other storage units between these areas in a warehouse is a highly effective method for separating people from vehicle traffic to avoid the risk of collisions. Where cohabitation of mobile robots and humans does occur, such as to support order picking in an aisle, an AMR equipped with autonomous navigation will provide far superior levels of safety. The faster the robot moves in one direction, the further the area of detection stretches, and the slightest obstacle entering the robot’s vicinity will trigger an emergency stop. Equipped with security cameras and LIDAR (Light Detection and Ranging) units, AMRs can travel on complex routes that are much narrower than alternatives such as AGVs can travel within, and they have a perfect perception of the environment around them. An iFollow robot, for example, analyses its situation in real time to avoid obstacles or even overtake slower vehicles. Two 3D cameras (front and back) give a threedimensional perception with a wide viewing angle and volumetric detection of objects even at long distances. Taking in the environment around them, the safety LIDARs complement each other perfectly

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Health & Safety

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and play an essential role in the 360° object detection of the vehicle. When the robot works in cooperation with humans, navigation modes can take into account the proximity of the user, for example during order preparation. A further safety design element comes in the form of an AMR that is 100% symmetrical and can navigate in both directions, which will avoid time-consuming and turning manoeuvres. Of course, using AMRs to transport goods across busy warehouse traffic routes not only keeps workers safely distant from busy warehouse traffic, it

Automated technology keeps robots under control so they do not become the cause of any collisions or stop where they are not supposed to thus causing a hazard.

also provides an aid to reduce strain related injuries. Some 1.6% of workers in warehousing suffer from work-related musculoskeletal disorders (new or longstanding cases), which is statistically higher than that for workers across all industries (1.2%). Pushing roll cages or manually carrying items around a warehouse will increase the risk of these injuries. With an AMR carrying the load, however, staff are free to concentrate on less physically strenuous tasks such as picking orders. As the miles transported and loads carried racks up on an individual mobile robot, its build will ensure it maintains its performance and reliability and therefore its safe operation. This is where robust build and quality engineering will set a range of robots apart, as is the case with iFollow AMRs. Automated technology keeps robots under control so they do not become the cause of any collisions or stop where they are not supposed to thus causing a hazard. AMRs will follow instructions from a Warehouse Management System (WMS) via robot fleet management

software, which should be capable of being implemented on any type of computer. A web application will allow managers to check in on the AMR via a smartphone. With a few clicks, locations can be modified, missions can be assigned to the robots and tasks scheduled. This is the kind of technology iFollow builds into its range of AMRs which are geared to improve productivity in grocery, industrial, pharmaceutical, chemical, cosmetic, logistics and mass distribution sectors, which all operate busy, fast moving warehouses. The company made the strategic choice to design and manufacture its own autonomous mobile robots – which are all guaranteed – and fully develops its own navigation and fleet management algorithms. Being designed for intense and repeated use over time, iFollow’s AMRs not only deliver great value and productivity, they also ensure safe operation.

Website:www.ifollow.fr.

Manufacturing & Production Engineering Magazine

Health & Safety

Helping industries return to a new normal GreCon can help you! GreCon makes people and places safer and enables the ‘smart factory’ as the leading provider of innovative industrial fire prevention and process measurement solutions. GreCon Limited is located just outside of Newcastle upon Tyne and is a member of the Fagus-GreCon Group. With a wealth of experience as a global market leader, GreCon demonstrates a strong understanding of customer needs and provides turnkey solutions for a wide variety of industries, including wood manufacturing, recycling, biomass, pharmaceutical, food, hygiene and more.

Fire Prevention to enable uninterrupted production

Fire Prevention or Fire Protection?

GreCon’s fire prevention technology protects industrial premises, processes and people, detecting and extinguishing ignition sources in mechanical and pneumatic conveying systems, filters, dryers, silos and other production areas, making workplaces safer and enabling uninterrupted production.

The adage, ‘prevention is better than cure’ rings true. GreCon believes that early detection of ignition sources is critically important. Once a fire starts, the results can be catastrophic. When companies are unaware of GreCon’s technologies, they rely on more conventional fire protection systems, which do not always provide the best defence.

We’re available for exploratory discussions and happy to conduct no-obligation surveys. Jonathan Hamill Left: Spark Detector GreCon DLD 1/9 - For the best detection performance in any environment Below: Intelligent Extinguishing Module GreCon IEM - Reliable extinguishing with integrated early wear recognition

Customers are particularly interested in the DLD 1/9, a highly sensitive spark, ember and hot particle detector for protection against fire and explosion in industrial processes. Intelligent Detection Technology IDT® provides optimal detection performance for all ignition sources in any environment and enables the detector to distinguish between dangerous sparks and harmless ambient light.

Enabling the Smart Factory A comprehensive range of industrial process measurement solutions equips the ‘smart factory’, helping customers improve product quality in their production processes, using proven German engineering to reduce raw material and energy costs, ultimately maximising operational efficiency. As businesses see a high demand for products, we are pleased to participate in many process improvement and optimisation discussions.

We’re excited that sales visits are back on the agenda! We were delighted to welcome Joshua McAree and Oscar Little to sales roles during 2021 under the sales leadership of Tom Burniston.

Manufacturing & Production Engineering Magazine

Health & Safety

Joshua has a BSc in Aeronautical Engineering, and Oscar holds a first-class honours degree in Mechanical Engineering. They are excited by the prospect of helping our customers improve their processes and increase the safety of their operations.

30th anniversary for GreCon Limited GreCon Limited is celebrating a significant milestone, with 30 years of business and commitment to the UK & Ireland market. During these 30 years, the company has focused on developing sustainable relationships with its customers and adopting

the role of a strategic partner. Founding GreCon Limited in 1992 enabled a more local connection and enhanced response times. As a result, customers across the UK & Ireland depend on GreCon for consultative and problem-solving sales engagement and first-class customer service. Managing Director Jonathan Hamill commented, “We’re available for exploratory discussions and happy to conduct noobligation surveys. Utilising our know-how, we believe we can play a vital role in helping industry tackle the current challenge, to emerge from the pandemic stronger and more resilient.”

Call GreCon today Today customers all over the world rely on GreCon. Please get in touch with us and discuss how we can help: sales@grecon.co.uk 0191 414 7200 www.grecon.co.uk

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Machining & Machinery

Motorsport subcontractor Races Ahead With Mitsubishi EDM Located within a ‘stone’s throw’ of the worldfamous Silverstone racetrack, it comes as no surprise that EDM Precision Technologies Ltd plays a major role in servicing the F1 and motorsport industries. Since its inception, the company has been machining precision components for a host of sectors that include aerospace, defence, medical, press and mould tools too. To carve a niche in the highly-competitive subcontract market segment, the Northamptonshire business has a specialisation in EDM technology – it is here that Mitsubishi wire EDM technology from the Engineering Technology Group (ETG) has helped set this company apart from its rivals. Extending the gap between itself and the competition, the company has invested in four additional Mitsubishi machines in the last four years. Now approaching 30 years in business, EDM Precision has a range of turning and machining centres, but with EDM drilling, spark erosion and 10 Mitsubishi wire EDM machines – it is evident where the expertise of this company lies. The company now has a Mitsubishi FX10K, QA10, FA20, FA20-S, two FA10-S, MV1200R, MV1200S, an MV1200S II plus an MV2400R, so it is safe to say that EDM Precision implicitly trusts the productivity, technology, reliability, service and support of the Mitsubishi brand.

the old machines, we strip them down and keep spares for the remaining machines – scrapping what is left. Of course, the newer machines are more precise, faster, more productive and quicker to set up.”

One-brand ambassador Looking at the current machine park that has more than 20 machine tools on-site, Paul adds: “We have a range of machining and metrology technologies on-site and at present, we have 14 Mitsubishi machines - 10 Wire EDM’s, three spark eroders and a Mitsubishi EDM hole drilling machine.” Alluding to why the company keeps investing in Mitsubishi machines, Paul has several reasons, saying: “When we bought our first one or two machines, we were impressed with the quality, productivity, service – the complete package. This gave us no reason to look elsewhere.” Looking beneath the surface, Paul adds: “There are three very good reasons for buying the Mitsubishi machines from ETG. Firstly, we are now experienced enough to service and carry out repairs on the machines ourselves. But when we do need external service and support, ETG is providing us with the service engineers that we have worked with for almost 30 years – this level of expertise is unparalleled. Additionally, we have built great relationships with the Mitsubishi service engineers and technical support teams over a long period, so they know our business, our machines and our requirements.” Investment strategy Looking at the strategy for continually replacing older machines with new technology, which has seen over 30 Mitsubishi machines through the doors at EDM Precision, Paul continues: “We tend to swap out the oldest machine for a new one. This is typically because the machines up to 20 years old are less reliable, incur downtime and have an increased maintenance requirement. Additionally, the older machines may have worn ballscrews and be less accurate, which only makes them suitable for certain jobs. Instead of selling

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Events & Awards News EconCore wins gold at the European Green Award 2022 European Green Award 2022, the winners are announced, honoring eco-heroes and sustainable solutions. The European Green Award celebrates outstanding results for a sustainable development and rewards companies and individuals who have contributed to the transition to a modern, resource-efficient, fair and competitive economy. This award serves as an inspiration and role model. It is organized by the European Institute of Sustainability. An international jury of experts, such as Dr. Andrea Grimm, co-founder of EAIS, Martin Neureiter, CEO of the CSR Company and Philipp Steinberger, Head of Investors ClubVenture awarded sustainable products, projects, marketing and change makers. EconCore’s “RPET Honeycomb Core Technology” was honored by the jury for its exemplary innovative performance in the field of sustainability: the RPET honeycomb core technology is not only an ecological technology solution with a high sustainability impact, but also offers weight reduction and a price advantage compared to conventional solutions and materials. In addition, the jury considers EconCore’s technology to be an

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excellent realization of a circular innovation that uses a high proportion of post-consumer waste as well as industrial waste into waste materials by reintegrating them into the production cycle. PP honeycomb products of EconCore technology are well established in automotive, packaging, transportation, etc. and already set an example of how performance, cost, weight and eco-efficiency can be combined at once. “It is an honor to win the European Green Award for our RPET honeycomb core technology. RPET honeycomb cores are made of 100% recycled plastic, sourced from both consumer and industrial waste”, says Dr Jochen Pflug, CEO of EconCore “this award is a testament to the hard-work and skills that the entire EconCore team have dedicated to developing such a sustainable technology – technology that doesn’t compromise on performance.” At the European Green Award 2022, the sustainability industry confirmed

great creativity and innovative spirit. 356 participants from 12 countries proved that sustainability knows no boundaries: “The excellent sustainable change makers who participated from Portugal, Spain, Belgium, Italy, Germany to Austria in the European Green Award 2022 have shown their outstanding commitment to sustainability. This year has shown that the Change Makers are in the process of implementing the idea of the Circular Economy into reality”, argues Dr. Andrea Grimm within the award ceremony and went on “with that, we can congratulate the 2022 winners first and foremost for their sustainability impact and thank them for being eco-pioneers who take on countless challenges to solve our ecological problems, rather than bemoaning them. We want to contribute to the transformation of economy, science and society, we want to make eco-heroes visible.” Descriptions of the nominees and winners can be found at www.europeangreenaward.com

Events & Awards News £12m investment drive pays off as William King secures major Jaguar Land Rover quality award One of the UK’s leading metals service centres is targeting further growth after it secured one of the automotive sector’s most demanding quality accreditations. William King Ltd, which specialises in hightensile steel, aluminium, light gauge processing, electrical steels and niche metal coatings, received the Jaguar Land Rover JLRQ Award earlier this month in front of 150 staff at its Atlas Centre facility in West Bromwich. Andrew McClure, Global Supplier Technical Assistance Director at the global car maker, made the presentation in recognition of the company’s outstanding performance over the past year where it has achieved world class ‘right first time’ and ‘ontime in-full’ delivery scores. It marks the culmination of a £12m investment drive by the firm over the last 5 years that has seen it introduce a new press blanking line, slitting facility and a state-of-the-art stacker, helping it take on new work and to create and safeguard more than 50 jobs. William King, which operates four technically advanced facilities in West Bromwich, Walsall, Washington in the North East and in the Czech Republic, adds value to supply chains by supply chain management, processing and just-in-time delivery of metals. The company currently works with several highprofile customers across the automotive, domestic appliance, metal packaging and general industry sectors, with the recent acquisition of Firsteel giving it the capability to provide specialist coated metals. This enlarged offering is already paying dividends, opening up new opportunities as the business aims to build on a growing order book that will see it hit over £150m turnover in 2022. William King has ten current vacancies, ranging from machine operators to apprenticeships in die maintenance and quality.

Young engineers hit the headlines with Design & Make triumph Three schools from the Black Country and Warwickshire have been crowned as the main winners at one of the biggest independent manufacturingeducation events in the UK. Ernesford Grange Community Academy, Great Wyrley Academy and WMG Academy for Young Engineers Coventry beat off competition from five other rivals to take the Manufacturing, Innovation and Efficiency titles respectively at the Design & Make Challenge 2022. The trio were joined on the podium by Alcester Grammar School, who claimed the first ever ‘Communications’ prize for its use of social media in promoting the day. Organised by the Manufacturing Assembly Network

(MAN), more than 35 students swapped their daily lessons for the chance to test out their design, engineering, prototyping and communication skills at the all-day event held at WMG Academy for Young Engineers in Solihull. Teams of four Year 11 and Year 12 pupils were set the challenge of using basic materials and tools to make a vehicle that could be propelled by a falling weight. They tested their devices, modified them and then raced them on a purpose-built 7.5m long track to see which one would complete the distance in the fastest possible time – a race that WMG Academy Coventry won in just 3.64 seconds. Ernesford Grange Community Academy, Great Wyrley Academy and WMG Academy Coventry all received a 3D printer for their efforts. This latest technology was kindly donated by 3DPRINTUK, who are specialists in low volume production using state-of-the-art powder bed fusion 3D printing systems with polymer materials.

Ernesford Grange Community Academy, Great Wyrley Academy and WMG Academy Coventry all received a 3D printer for their efforts.

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Measurement, Sensors & Monitoring

Sensors and Instruments: Supporting the Future of Technology Look around and you will notice that we live in a world full of sensors and electronics equipment. Automatic lights turn on when you walk into your office. The room temperature automatically adjusts according to the weather. Even making your morning cup of coffee can involve sensors at play.

Digital and electrical sensors can detect everything from light to distance and measure real-world quantities such as light, pressure, humidity and moisture, which are then converted into electric signals.

As the era of digitisation progresses, we are seeing the sensors and instruments markets developing through a crucially formative stage, with massive potential for growth across industries such as IT, communication, entertainment and home appliances. So, what is driving growth in this market, and how are modern sensors and instruments supporting the future of technology and innovation? Surrounded by sensors These days, sensors and electronic instruments are fundamental to most of our products, production systems and technological infrastructure. Digital and electrical sensors can detect everything from light to distance and measure real-world quantities such as light, pressure, humidity and moisture, which are then converted into electric signals. These signals can be interpreted by humans or fed into computer systems to deliver various outputs.

SICK Launches Cost-Cutting Energy Monitoring of Compressed Air As manufacturers face rising energy bills, SICK has launched the FTMg with Monitoring App, an Industry 4.0 solution that helps them see the data they need to reduce energy consumption through better control of compressed air. The SICK FTMg with Monitoring App enables production and maintenance teams to monitor compressed air continuously so they can reduce leaks, improve operating efficiency, and cut costs. Using data from strategicallypositioned SICK FTMg flow meters, the cloud-based SICK FTMg Monitoring App visualises a wealth of both real-time and historic data. It enables continuous energy management, condition monitoring and predictive maintenance of compressed air systems from any internet-enabled device. Targeted Energy Reduction The SICK FTMg with Monitoring App is a scalable system that can target the compressed air energy use of individual machine cells through to

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entire production or logistics halls. With no programming needed, it can quickly start visualising continuous compressed air data in a way that is easy to use and interpret. As well as enabling more

Electronics instruments work alongside sensors to indicate or record physical values like voltage, power, temperature and frequency. This equipment can help to diagnose faults in an electronics system and determine that it is functioning correctly. Demand for an immersive experience from digital products with superior quality, energy efficiency and high definition has propelled the need for more sensors in consumer electronic devices. For example, the single most significant driver for sensors in consumer electronics is the growth of the tablets and mobile phones market. The maturation of these devices is driving the rapid proliferation of image sensors — a global market expected to grow at a CAGR of 8.4% by 2027. On a larger scale, the rise in demand for sensors and instruments can be attributed to the development of smart cities. Smart cities combine data and digital technology to empower

sustainable use of resources, the data insights support better operational efficiency and help achieve reduced carbon targets, contribute towards ISO50001 Energy Management certification or compliance with the UK Government’s Energy Saving Opportunity Scheme (ESOS). Website: www.sick.co.uk

Measurement, Sensors & Monitoring businesses and individuals to make better decisions and improve quality of life, utilising a mass of smartphones and sensors connected by high-speed communication networks. Driving the digital era The evolution of electronic sensors and instruments benefits a broad range of businesses and customers, with smaller, smarter components and devices allowing for unprecedented innovation. But to take new products from concept to reality and meet heightened demand, the electronics manufacturing industry must remain one step ahead. As a result, electronics manufacturing is changing at lightning speed, combining with the advanced capabilities afforded by Industry 4.0 and the internet of things (IoT) — a global network of connected devices and a rapidly changing technology industry. Intelligent, internetenabled sensors are changing how manufacturers capture and communicate information for research, testing, product realisation and development, with the adoption of cloud-based technology solutions and smart production driving digitisation within the industry. Delivering quality and innovation Sensor development and advanced manufacturing go hand in hand. Electronics created to improve the accuracy and scale of electronics

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manufacturing services (EMS) will, in turn, help to design and develop future consumer technology products — but only when quality remains a priority. In today’s digital world, the margin for error is shrinking as competition ramps up and customer expectations rise. Plus, with the climate crisis at the forefront of public attention, electronics manufacturers have a duty to develop components and devices that can stand the test of time and conform to environmental standards.

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Smart cities combine data and digital technology to empower businesses and individuals to make better decisions and improve quality of life, utilising a mass of smartphones and sensors connected by high-speed communication networks.

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Measurement, Sensors & Monitoring Asset Tracking for Planned Preventative Maintenance Whether you’re managing a manufacturing line, facility or any other business that relies on equipment to function, unforeseen repairs and breakdowns can lead to disaster. Fortunately, preventative maintenance can prevent this. No manager wants their smooth working processes ruined by unexpected equipment failure. These failures will create unexpected expenses through the loss of productivity, a loss that will grow until the machine is repaired at a high cost. Planned preventative maintenance addresses this issue and has become a commonly adopted part of any maintenance schedule for many industries and sectors, thanks to its many benefits.

Why Is Preventative Maintenance Important? Older maintenance programs are built on a reactive model. These initial plans were designed around waiting for something to go wrong with your essential equipment and ensuring it is fixed most efficiently. Unfortunately, this reactive method has inherent problems, the largest of which is that it’s reliant on a problem existing for even a small amount of time while you get it fixed. As a result, these older methods have since been replaced with superior, predictive models. Planned preventative maintenance (PPM) has several similar names, such as scheduled or preventive care, but they are all aimed at a similar goal. PPM is a proactive approach to your maintenance schedule, where you pre-emptively plan maintenance work ahead of time, monitor the state of your equipment, and prevent costly breakdowns. As a result, PPM will increase efficiency, decrease equipment downtime, promote health and safety and save you money in the long run. Planning is an essential part of asset maintenance management as it gives you the benefit of choosing when your equipment will be unavailable and compensating accordingly with either the timing of your maintenance or bringing out alternative equipment temporarily.

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plan is easy. Many unique ideas are recommended for effective maintenance plans, but you must customise them to suit your asset’s individual requirements to get the most out of them.

What is Asset Maintenance Management? The essential goal of effective asset management is to ensure that you profit from your assets as much as possible. Maximising the value of your purchases covers a wide range of assets, but the most relevant here are physical items and equipment that help you run your business. Six main elements of effective asset management can help managers get the most out of their investment. These consist of, identification, location, condition, specification, maintenance and cost. Identification is quite a straightforward initial step. This is where you record what assets you have, so none miss regular maintenance. The struggles with this come when you manage hundreds of assets across several sites. Digital alternatives have substantially improved paper and pen record-keeping and developed sophisticated asset tracking systems to make this straightforward, and these are elaborated on later in this article. Monitoring the condition of the asset is essential for asset maintenance management. One reliable way the data on the state of your equipment can be obtained is through visual inspections, but knowing when the right time is to conduct that inspection is made significantly easier with the assistance of digital tracking systems. These systems can alert a manager’s computer to the arrival of the regularly pre-planned maintenance dates so equipment can be checked easily. Understanding your assets’ condition requires understanding its specification, capabilities and safety requirements. These are limitations that need to be followed to use your asset correctly. For example, overtaxing a machine will decrease its working life even faster. Knowing the specifications of your asset will give you a starting place for comparing its condition in the future With these steps in place, creating a planned preventative maintenance

Finally, we have the cost of the asset. Not just covering the initial investment, this also includes the maintenance costs. Any piece of equipment ages, and it can potentially operate less efficiently as time passes. By monitoring the asset’s performance and maintenance requirements and comparing them to the initial costs, you can decide if it is still worth the price.

How Does Asset Tracking Help? Asset tracking is essential to effectively plan preventative maintenance within your existing maintenance management programs. With our range of fixed asset tracking labels, you can tag your valuable assets and digitally connect them to your digital asset tracking system. When combined with our professional software, you can generate your own asset numbers and print labels using thermal transfer printers on either fixed or mobile printers, enabling point of application labelling. Our popular G-Smart assets software can track and locate any tagged assets through a web-based program. In addition, this simple and intuitive platform compiles your tracked assets within a secure system whilst being available remotely if needed. This flexible application is designed to manage asset maintenance across multiple locations by providing you with their real-time location and maintenance program details. Inside this software is a PPM module that enables you to create maintenance checklists. This can be connected to mobile computers so, for example, your field engineer can be guided through the maintenance process and confirm the checklist steps as they work; this process can update the database in real-time, leaving no room for human error.

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Events & Awards News

Rushlift celebrates fourteen employees’ long service milestone Rushlift, the specialist materials handling and airport ground support equipment and service provider, has proved that it’s a “great company to work for”, say staff, with a list of fourteen employees celebrating longservice achievement awards in 2022 – in all, totaling 340 years of continuous service. Carl Whyment, Managing Director at Rushlift says: “This is a remarkable achievement for everyone concerned. So many of our loyal and hardworking team members are celebrating

Composite Sandwich Conference - CSC 2022: global experts present latest developments Over 100 composites and sandwich construction experts from around the world have spent two days exploring the technical challenges of how to strip weight from transport using honeycomb cores. The experts attended the joint Thermhex and Fraunhofer IMWS CompositeSandwich Conference held in Halle (Saale) at the end of May (24 – 25 May 2022). The delegates were shown the latest research, covering a wide range of areas, including among others: • Principals of sandwich technology for airframe and interiors; • Thermoplastic sandwich composites – novel processing in automotive; • The design of composite sandwiches for train car body shells; • Automated fibre placement for sandwich parts in helicopters; • Multi-scale modelling and the future of the composite sandwich technology. The conference provided the

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opportunity for engineers and scientists from across the composites sector to explore new fields of application and network with some of the leading minds in the sector. The construction of sandwich materials, based on fibre-reinforced plastics, enables highly efficient lightweight structures and is making an enormous contribution to resource conservation in a large number of industries. Using sustainable sandwich material reduces not only weight but at the same time the CO2-footprint. Composite sandwich materials are used where an optimum strength to weight ratio is crucial. ThermHex Waben’s polypropylene lightweight sandwich panels have been used in the manufacture of trucks, ship interiors, prefabricated bathrooms and modern swimming pools. Dr Jochen Pflug, CEO of ThermHex said: “Honeycomb sandwiches are gaining increasing usage in a wide range of industries.

“I am constantly amazed with the creativity of the industry in applying this technology, efficiently and effectively and excited about the future applications and potential of composite sandwich materials.” “The conference enabled a very productive exchange and brought many new insights, for example on the need for cost-efficient composite sandwich structures and their processing by automated production methods, the reliability of the components produced with them, or even new possible applications for sandwich technology”, summarizes Dr. Ralf Schlimper from the Fraunhofer IMWS. “The very positive response shows how huge the potential of the technology and the interest among companies is, especially in the field of mobility systems, to tap into it.” The keynote speech of Professor Axel Herman of CTC Stade, an Airbus company and the University of Bremen to open the conference at the German National Academy of Sciences Leopoldina was given be Tassilo Witte. Other speakers came from some of the leading companies across the industries, including Beyond Gravity (formerly Ruag), Airborne, Elring Klinger, Engel, Fraunhofer IGCV, Fraunhofer IMWS and Econcore. Delegates were also able to visit ThermHex Waben’s production facilities and the Fraunhofer pilot plant Centre for Polymer Synthesis and Processing PAZ to get an insight view of the potential of efficient production technologies for thermoplastic sandwich structures from ThermHex’s semi-finished Organosandwich products to 3d formed and functionalized parts via Fraunhofer IMWS’s TS-Moulding Technology.

Events & Awards News I would like to congratulate and thank each one of them for their dedication, hard work and for the passion with which they have performed their individual roles. Carl Whyment

very significant work anniversaries this year – several with 40 or 30 years of service, and many more set to reach their 15, 20 or 25 year milestone. I would like to congratulate and thank each one of them for their dedication, hard work and for the passion with which they have performed their individual roles.” He adds, “This collective bank of experience, skills and knowledge, accumulated over so many years, is a very rare and valuable resource for our business – and a resounding endorsement for Rushlift as a great place to work.” Founded in Bishop Auckland in 1978, the company has grown to become a nationwide materials handling service operation with six sites located across the UK – from Cornwall to Aberdeen, and throughout Ireland – employing over 200 people. The business now offers forklift contract hire, short-term rental, new truck sales, and reconditioned equipment, along with full nationwide service engineering, maintenance and parts support. A separate division, Rushlift GSE, provides ground support equipment, financing and servicing for some of the UK’s largest airlines. Four of the longest serving employees are from the 130 strong engineering and technical support team: Andy Webb (30 years), Keith Smith (25 years), and Mark Duffield (25 years) are all highly experienced and dedicated forklift truck field service engineers and are keen to continue working on keeping customers’ fleets in tip-top condition for many more years to come. Technical manager, Keith Wedgewood (40 years), started out as a service engineer based at Bishop Auckland, when it was the only site, and is now bringing his knowledge and expertise to bear on ensuring that the service operation runs smoothly. A further six employees celebrate 20 years working for Rushlift in 2022: Andy Gazzard, Gary Alderson, Carl Aylett, Peter Hutchings, Mark Pearson and Stephen Winter, with two more, Elaine Dennis and Andrew Patrick, serving 40 years and 30 years respectively. In addition, Sarah Conroy and Elaine Tilley will be celebrating 15-years with the company.

Alok Sharma MP officially opens Tower Cold Chain’s global HQ The global headquarters of pharmaceutical thermal protection specialist Tower Cold Chain has been officially opened by The Rt Hon Alok Sharma, Member of Parliament for Reading West. Tower Cold Chain manufactures robust, reliable and reusable supply chain containers, which are used

worldwide to transport temperaturesensitive pharmaceutical, life-science and biotech products. A fast-growing business, Tower recently won the Queens Award for International Trade. The company moved to its bespoke 26,000 sq ft facility in Theale in September 2021. The building has helped Tower to greatly expand its container conditioning and storage capacities, as well as enhancing its design, laboratory and testing capabilities. As well as being located in his constituency, Tower’s work is of particular interest to Alok Sharma due to his role as President of the COP26 summit. He had already visited the site to see first-hand the role it has played in transporting COVID vaccines in a safe and sustainable way, so he was delighted to be asked to officially open the headquarters. Alok said: “It’s great to see how Tower has continued to thrive since my visit in November and I am delighted that its work has been recognised with a Queen’s Award for International Trade. As a fast-growing, innovative business, Tower reinforces the fact that Reading is an economic powerhouse and provides great tech job opportunities.” The official opening was also attended by members of the Tower board. Chairman Just Arne Storvik said: “The Theale facility offers worldleading technology to support the needs of pharmaceutical companies, airlines and logistics providers. We’re proud to see the facility officially opened and honoured to have such an esteemed dignitary as Alok Sharma here to cut the ribbon.”

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Product News OXECO secures $10.5 million to advance surface treatment products in clean energy, transport sectors OXECO, a chemistry technology company transforming product design and manufacturing, today announced the closing of a $10.5 million funding round secured by new Chief Executive Officer, Vassilis Ragoussis. The funding round is led by Lansdowne Partners, with participation from Ora Capital Partners, Tanarra Capital, and the Goh family office. “As demand for industrial production surpasses pre-pandemic levels and net-zero deadlines loom, urgent action is needed to accelerate new product innovation whilst optimizing productivity at scale,” said Ragoussis. “This investment will expedite our ability to support partners in bringing highly innovative clean energy products to market and address workforce shortages, supply chain challenges, and soaring energy costs.” OXECO’s proprietary technology platform ONTO™ improves the way materials interact in their intended environment by leveraging reactive carbenes to control the adhesion and wetting properties of surfaces. The technology optimizes the surface treatment of painted products and allows designers to modify the surface of materials to develop novel products. Today manufacturers and designers are exploring applications in clean energy components including wind turbine blades and batteries. One of the company’s partners, a leading producer of finished composite parts, has been using OXECO’s technology to solve bottlenecks in the painting of automotive parts for Fortune 500 companies and to maximize an existing workforce and space. The funding will be used to further commercialize the company’s technology and advance R&D across the clean technology and transport sectors.

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Fifth Nakamura Rampsup Productivity at Velden As part of its continued investment strategy, Velden Engineering (UK) Ltd has just taken delivery of a Nakamura-Tome NTY3-150 twin spindle 3-turret turning centre from the Engineering Technology Group (ETG). Delivered in March, the new addition has been purchased to produce high-volume components beyond the size capacity of the company’s sliding head turning centres. Based in Bolton, Velden was the first UK job shop to achieve ISO: 9001 in 1987 and has since won a multitude of prestigious OEM contracts and awards along the way. The Lancashire subcontract manufacturer now offers a complete range of services from CNC machining, laser cutting, waterjet machining, sheet metalwork, assembly, design and development and more. The company now serves clients in sectors as diverse as nuclear, offshore, rail, motorsport, aerospace, automotive, environmental, medical and pharmaceutical. In 2012, the manufacturer acquired its first Nakamura-Tome turning centre, a compact WT100 twin-spindle twin turret machine. This formed part of a strategy to replace older machines with modern multi-tasking machines to reduce the number of operations and improve efficiency. Commenting upon this, Velden Engineering’s Lee Valentine, Plant Manager says: “Originally, Velden was looking to buy a different brand of machine, but we were impressed upon seeing a Nakamura WT100 at an exhibition. When we learnt that the next generation of this machine was about to be launched with a new large screen Windows-based control, the decision to purchase our first Nakamura, the WT100 was made on the back of it fitting perfectly with Velden’s Industry 4.0 aspirations. Velden became one of the first companies to take delivery of this next generation machine, which became an instant success. The machine is very reliable with higher overall equipment effectiveness that made it particularly impressive to all customers and visitors who saw it in action.”

The relationship with ETG blossomed and in 2013, the company took delivery of a larger Nakamura-Tome WT150II twin spindle twin turret turning centre with an upper turret Y-axis after winning a new contract. Four years later, a second WT150II was planned to service an increase in demand, but with no machines available in European stock at that time, ETG loaned Velden an AS200 until the second WT150II arrived. As it turns out, the Nakamura AS200 was perfect for certain lower volume projects with its fast set-up and programming. The result was Velden taking delivery of the second WT150II and also purchasing the AS200 that had been loaned. As part of its continuous improvement strategy, the company replaced its oldest Nakamura, the first WT100 machine that arrived almost a decade ago with a brand new WT150II that arrived in November. This has now been followed by the new Nakamura-Tome NTY3-150. Prior to the Nakamura-Tome NTY3-150 arriving, Lee said: “Many of our enquiries are now for parts in higher volumes with increased complexity that are above the size parameters for our sliding-head machines. As a 3-turret machine all with Y-axis, the Nakamura NTY3150 machine opens up a greater opportunity to do even more simultaneous machining and it will deliver even faster cycle times. This will be possible through the use of special tooling on what will be very price-sensitive parts. The additional cost of the Nakamura NTY3-150 will be offset by allowing us to be even more competitive on certain packages of work and it will therefore enable us to win a lot of new business off the back of it.”

Product News

hyperMILL Revs up Productivity for Motorsport Manufacturer Founded in 2016, subcontract machine shop HSM Components in Deeside has recently invested in CAD/CAM software from OPEN MIND Technologies. Specialising in the manufacture of bespoke components for customers across a multitude of industry sectors, the North Wales company recently reached the capability limits of its previous software – and that is where the hyperMILL CAM system has stepped in. “I had pretty much reached the limits of my old software, so I needed to get something more advanced. hyperMILL was the perfect choice for my business,” says Steve Rigby, Managing Director at HSM Components. The previous CAM system was creating a level of frustration at HSM, especially on more challenging components. Alluding to this, Steve says:

“In comparison to our previous system, it’s like comparing a Ferrari to a pushbike. The old software was more geometrybased, so if you had a complex part - it really did become an exercise in CAD skills. Now, with hyperMILL, it works off surfaces and surface edges, so it is all model-based. There is also a lot more functionality to the system. Initially, I found hyperMILL a learning curve as it is more advanced, but the more time I invested in the system, the more I got to grips with it. The possibilities for our business are incredible.” The Flintshire manufacturer recently won an order to manufacture big-bore billet engine blocks on Suzuki Hayabusa motorcycle engines for a motorsport customer – a project the company would not have been able to undertake without hyperMILL. The challenging project also required specialist tooling to machine the engine blocks from

aluminium 6082 billets. Referring to the motorsport project, Steve says: “I wouldn’t have been able to take this part on with the old software. hyperMILL has helped immensely and made this project possible. One of the biggest positives is the hyperCAD-S system from OPEN MIND. When you come to doing off-line programming, not everything is straightforward. Very often you have to do quite a bit of CAD work, such as creating surfaces and containment boundaries. With the hyperCAD-S system within hyperMILL - it’s very easy to use and it has excellent surfacing tools.”

First RISC-V-Based System-on-Chip (SoC) FPGA Enters Mass Production Microchip’s Mi-V ecosystem has enabled customers to ramp products based on PolarFire® devices more quickly, from prototypes to production. The first SoC Field Programmable Gate Array (FPGA) to support the royalty-free RISC-V open Instruction Set Architecture (ISA) has entered volume production, marking a major

milestone in the evolution of embedded processors. As customers continue to adopt PolarFire® SoC FPGAs at a rapid pace, Microchip Technology Inc. (Nasdaq: MCHP) announces the production qualification for the MPFS250T and the previously announced MPFS025T. Microchip also announces that its Mi-V ecosystem continues to streamline RISC-V

adoption while enabling a new class of smaller, more power-efficient and lesscostly industrial, IoT and other edgecompute products. PolarFire SoC FPGAs unlock new configurable processing opportunities with their hardened real-time, Linux®capable RISC-V-based microprocessor subsystem on a fast FPGA fabric, backed by Microchip’s commitment to a product roadmap and longterm availability. They also leverage customizations enabled by the openstandard RISC-V ISA to enhance power efficiency, security and reliability as compared to alternative processing options, while introducing valuable new capabilities such as the deterministic Asymmetric Multiprocessing (AMP) mode allowing users to run a Linux OS while running a maximumperformance, real-time application. The PolarFire SoC’s innovation enables new solutions to challenges such as improving computational power efficiency and delivering compute acceleration at the network edge and delivering unmatched capabilities for communications, defense, medical and industrial automation applications.

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News

Encore Launches Second New Division in Six Months Award winning and fast-growing Midlands recruitment agency Encore Personnel is expanding for the second time in six months with the launch of a new Engineering Division in Derby. Following the news that the 200-strong specialist recruiter aims to push through the £100m turnover mark this year, it has taken on expert

Engineering consultant Richard Glennan to head up its newest division which will be run out of Encore’s Derby city centre branch. The latest opening follows the launch of a brand-new division for the business in January which specialises in attracting and retaining exceptional Maintenance Engineers. Richard, who has 10 plus years’

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experience in the sector and a standout track record of successfully launching start-up recruitment divisions in the region, plus hands-on knowledge of engineering, said: “Having started my career with an apprenticeship in welding and fabrication, I have a firm understanding of the sector and that foundation has served me well so far in growing teams which find the right people for the right roles, first time. “There’s an exciting opportunity to expand Encore’s footprint in the engineering sector and with a decade’s worth of experience, six of those years being in a management role, I’m confident we will quickly grow our network into the Derby engineering market. Basing our approach on a very successful model - which is working hard for our clients in our other Engineering locations - we will be, as is the Encore mission, imaginative and client focused in how we package our solutions and sensitive to the individual requirements of each business we work with.” A combination of factors have lined up in the creation of this new division, such as an increase in British production and manufacturing across a range of sectors as the industry is recovering to its pre-pandemic position. Richard aims to appoint a quality service team by the end of the year which will allow him to increase business outturn by 150% by the end of 2023.

News Farnell’s e-Tech Journal Edition 2 now available for download Farnell, an Avnet Company and global distributor of electronic components, products and solutions, has published the latest edition of its popular online magazine, e-Tech Journal. In edition 2 of the recently relaunched journal, Farnell helps users understand the challenges that many engineers face when delivering power safely, reliably, accurately, and efficiently. By downloading the latest edition of the free magazine, readers can learn how to select the best battery for their next wireless application and how to overcome battery-life challenges. In addition, users will be given an insight into the benefits of 4th generation SiC MOSFETS, circuit protection solutions, design considerations for auxiliary gate drive transformers, and how to overcome space constraints in power management applications. Users can also discover how the latest low-power, energy-efficient devices and system designs have transformed power management, allowing for the use of fewer devices, resulting in more reliable and cost-effective solutions plus read technical content from leading suppliers like Renesas, Analog Devices, Wurth Elektronik, Keysight and many more. Cliff Ortmeyer, Global Head of Technical Marketing at Farnell, and Editor of the e-Tech Journal, said: “We are delighted with the new look e-Tech Journal as we continue to provide in-depth technical insight into new technologies, along with analysis and explanations from suppliers, industry experts, and Farnell engineers on key trends shaping today’s electronics industry. “I am sure this latest edition will prove to be extremely popular with readers as we help them to better understand power management and the inherent trade-offs required to unlock innovation.”

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Edition 2 is now available as a free download here, and readers can already look forward to the third issue due in August, with a focus on Smart Industrial Automation.

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Company News

IES increases turnover by almost a third since start of pandemic IES, a global provider of equipment moving services, logistics, and project management in high technology industries, published its annual results and announced an increase in turnover of almost a third since the start of the pandemic, with 22% in the past year. In 2021/22, the company recruited new engineers and commercial specialists, who now account for 15% of the total workforce. It is currently building its team to take account of some recent new business wins, from existing and new customers. One of the company’s apprentices, Harri Green, was a finalist in the Outstanding Apprentice of the Year Awards in the engineering and manufacturing category in a major regional award scheme. He was the only student in his college’s history who achieved a perfect score across all of his subjects. Last year IES managed many projects, including: • Moving and installing over 18 tonnes of specialist equipment, much of which had to remain under clean room conditions, for Catalent, a pharma and

biotech global leader. This included positioning 3.5m towers each weighing a tonne within a 4m tall building; • Moving and re-installing 15 high technology machines weighing over 25 tonnes, including the 17 tonne Suspension Parameter Measurement Machine, to engineering consultancy AB Dynamics new Engineering Design Centre; • Celebrating a 10-year partnership with global technology giant HP, during which the company successfully completed over 180 installations and upgrades of HP’s industrial and large-format printers around the world. The company also celebrated its 30th year of operations. Founded in 1991, it

now operates from a 30,000 square-foot facility in Bristol. Niels Morch, IES’s co-founder and Managing Director, said: “Last year was pretty busy as equipment moves and installations that had been shelved due to the pandemic came back on stream with a vengeance. “I am really pleased that my team has been able to meet these challenges, continuing to give our customers what they need time and time again, and that more companies look to IES for complex technical moves and equipment packing services. “The coming business year is shaping up to be just as good as last and we are looking forward to staying at the forefront of high technology machinery relocations & installations.” IES works closely with clients in semiconductor, pharmaceuticals, print, aviation, automotive and general manufacturing, among many others. IES is forecasting strong growth for the coming year. Evolving along with technology trends, IES specialise in decommissioning, relocation and re-commissioning of complex equipment and production lines, as well as complete factory moves. IES also re-engineers, maintains and upgrades equipment in the UK and worldwide. IES offer resource support on short-, medium- or long-term contracts for on-site engineering, technical services. They are a trusted provider of compliance assessment and testing for UKCA Marking, CE Marking, and Low Voltage, Electromagnetic Compatibility and Machinery Directives work. For more information on IES, please visit www.ies.co.uk

‘Strength in numbers’ key as manufacturers urged to consider Flexible Purchasing as a way of beating escalating energy prices Manufacturing SMEs are being urged to consider flexible contracts as a way of staving off escalating energy costs. Control Energy Costs, which works with hundreds of companies across the UK, has seen a 50% rise in the number of firms looking at this form of ‘purchasing’ and is now offering industry the chance for businesses to pool their usage together as a collective. This means they will be able to take advantage of Flexible Purchasing for the first time, as normally it is only reserved for organisations that tend to consume more than 10,000,000 kWh per annum

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and thus require a more sophisticated buying strategy. This approach is not new, in fact Control Energy Costs launched the ‘Wholesale Market Access’ basket in

2018 to offer this very method within a collective agreement. It has proved successful for those involved, but the number of organisations wanting to take part has increased rapidly in the last six months and the business now has more than 50 companies involved in the framework with more waiting to join. Recent sign-ups include global manufacturers, SMEs and construction businesses, who have - on average seen a 150% rise in energy prices on what they were paying in 2021. For further information please visit www.cec.uk.com

Company News In-Comm Training lands major apprenticeship contract with automotive supplier A leading independent training provider is celebrating winning its largest apprenticeship contract in years after signing a major deal with Lander Tubular Products. In-Comm Training, which operates three state-of-the-art technical academies across the Black Country and Shropshire, has become the strategic training partner for the supplier of precision engineered metallic and plastic manipulated pipe assemblies for the automotive, commercial vehicle and off-highway sectors. Forty Level 2 apprentices in Lean Manufacturing Operations will be recruited over the next six months in a bid to develop a future talent pool that can help the manufacturer meet a rapidly growing order book. The new relationship will cover all recruitment and selection, advice on tapping into funding, induction process and delivery of training, with In-Comm trainers and assessors set to be permanently based at Lander Tubular Products’ internal academy at its Woodgate Business Park factory in Birmingham. Growing its own staff has always been a priority and this new contract marks the next phase of its workforce development, with pathways being created so that individuals can work all the way towards Technical Apprenticeships, a Degree in Engineering and Manufacturing and upskilling opportunities in continuous improvement, quality and leadership & management. For further information, please visit www.in-comm.co.uk or www.lander.co.uk

Whitcombe Pipelines steps on the gas with £2m HS2 contract A strategic partnership developed in the Black Country - has helped a gas distribution and reinstatement specialist secure a major £2m contract to work on the UK’s premier rail project. Whitcombe Pipelines (WPL), which employs 160 people at its base in Rowley Regis, tapped into Wolverhampton’s National Infrastructure Solutions (NIS)’ unique ‘Recruit, Train, Retain’ model to pass all the requirements for working on HS2. The Achilles-registered company will complete reinstatement works for gas pipelines, as well building new access roads and verges. WPL anticipates more than 40 people will be employed across several project locations at any one time, as it supports the biggest rail revolution in the UK’s modern history.

It marks what has been a major year of growth for the Black Country firm, with sales doubling to £10m over the past twelve months. HS2 isn’t the only big win secured by Whitcombe Pipeline in recent months, with a touch of innovation helping it impress Cadent. National Infrastructure Solutions, which provides specialist training for the rail, infrastructure and construction sectors, was again heavily involved, developing a workflow app for the UK’s largest gas distribution network’s design and build process. Whitcombe Pipelines and NIS are in discussions about introducing bespoke industry specific courses to support WPL’s move into major civil engineering projects across the West Midlands and beyond. For further information, please visit www.nisgroup.co.uk

Manufacturing & Production Engineering Magazine

Data Management How manufacturers can overcome data management challenges that come with rapid digitalisation By John Cheney, CEO, Workbooks

The manufacturing industry has seen significant growth in technological adoptions across production facilities over the last couple of years in order to improve productivity, deliver great value to customers, and remain competitive. However, rapid digital transformation brings a number of challenges, such as how to manage increasing volumes of data. 61 per cent of organisations believe data management challenges, such as identifying new customers, streamlining operations, and driving efficiency, have slowed or will slow the automation of their business processes. Further to this, sales teams increasingly need easy access to real-time data, deeper customer insights, and the tools to close deals quickly and efficiently. In the manufacturing sector, the rise of unexpected costs in other parts of the business is delaying buying decisions: for instance, energy prices and cost of goods equate to a major part of overall costs. So then it becomes a battle between slowing down or accelerating quickly. To address these needs, a growing number of mid-size manufacturers have turned to cloud-based CRM (Customer Relationship Management) and Enterprise Resource Planning (ERP) technologies to grow their way out of downturn, increase customer lifetime value through more effective sales, marketing and services, achieve greater operational efficiency,

The digitalisation of manufacturing processes has enabled many to gain a competitive edge: when done right, customer service can become a strong competitive advantage too – and even be transformed into a revenue stream for the business. and improve collaboration throughout the business.

Addressing sales and marketing challenges with digital transformation Over the past few years, the majority of manufacturers have recognised the importance of new technology in improving customer intelligence. However, the key objective for most is generating efficiencies within their manufacturing facilities, whilst keeping costs of implementation and operation

low. But revenue growth is also reliant on today’s sales and marketing teams being able to sell faster and smarter, and to focus efforts on the right opportunities at the right time. Likewise, while most manufacturers understand the importance of their service department in driving the right customer experience, many are still using spreadsheets or paper-based systems to track customer information, including purchase history and service requests. Many still have engineers printing out service tickets to take on customer visits. Manufacturers need to adapt sales and service models to keep up with customers’ needs and expectations. The digitalisation of manufacturing processes has enabled many to gain a competitive edge: when done right, customer service can become a strong competitive advantage too – and even be transformed into a revenue stream for the business. For instance, 60% of customers stop buying into a brand after one poor service experience, while 67% of this churn is preventable if the customer’s problem is resolved during their first interaction. That means excellent customer service not only retains your customers, but potentially leads to acquiring customers from competitors too. This is also why many are embracing new CRM technologies which enable manufacturers to streamline operations and drive efficiency throughout the entire lead-to-cash process – all while delivering customer service excellence. This technology enables manufacturers to improve productivity in their sales functions and boost their competitiveness.

Integrating ERP and CRM Creating an automated exchange of data between CRM and ERP systems provides a bridge between sales, marketing, customer service and production, encouraging greater collaboration across organisations. Linking systems together opens up a flow of data that can be turned into information and insights and acted upon quickly. ERP systems do a great job of managing the order-to-invoice process, including manufacturing, billing of materials, stock control, invoicing and accounting, but

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Data Management sales teams can review stock availability, product warranties and maintenance contracts. And by having access to stock control and production information, sales reps can better manage their sales pipeline, and manage customer and channel expectations.

Conclusion Manufacturing is undergoing a transformation that some refer to as the fourth industrial revolution (or 4IR). For many manufacturers, 4IR is about gaining insights to help improve productivity, deliver greater value to customers and remain competitive.

they are often poor at supporting the sales and marketing processes within a business, so a best-of-breed approach is often the most successful. Being able to market to clients effectively requires having transaction data in ERP and CRM systems, and integration allows sales and marketing teams to use existing customer knowledge to full effect. Profiling existing customers by industry,

purchase history and historic revenues allows teams to upsell and cross-sell to existing clients more effectively. It becomes easy to promote new products to customers if marketing teams can identify all the clients that bought previous products. This two-way stream of information provides production teams with pipeline visibility so they can plan production schedules accurately, and

Digital transformation has taken many organisations as far as improving processes and automating systems, but this often comes at the price of creating siloed internal structures. The next phase of digitalisation calls for closed loop systems where processes can be streamlined and data can be harnessed in real time. CRM is an effective enabler of these ambitions: it improves the way manufacturers manage data. This, in turn, generates new revenue opportunities for manufacturers and improves efficiency.

Microchip Expands Its Portfolio of MPU-Based System-on-Modules (SOMs) with the SAM9X60D1G-SOM As the embedded market continues to grow rapidly and evolve, developers are seeking to optimize product development, or they may need to transition from a microcontroller (MCU) to a microprocessor (MPU) to handle increased processing requirements. To help developers with this transition and reduce design complexities Microchip Technology Inc. has announced it has expanded its portfolio of microprocessors system-on-modules (SOMs) with the SAM9X60D1G-SOM ARM926EJS™-based embedded MPU running up to 600 MHz. Software for the SAM9X60D1G-SOM is available with bare metal or RTOS support through MPLAB® Harmony3, or complete Linux® mainlined distributions. The SOM, based on the SAM9X60D1G System in Package (SiP), is a small 28 mm × 28 mm handsolderable module that includes the MPU and DDR in a single package,

along with power supplies, clocks and memory storage. The SAM9X60D1GSOM is Microchip’s first SOM equipped with 4 Gb SLC NAND Flash to maximize memory storage of data in application devices, while the on-board DDR reduces the supply and price risks

associated with memory chips. The small-form-factor SAM9X60D1G-SOM also includes an MCP16501 power management IC (PMIC), which simplifies the power design effort to a single 5V voltage rail to enable lower-power systems.

Manufacturing & Production Engineering Magazine

Robotics

Precision is no ‘pipe dream’ for Pipetronics As a manufacturer of highperformance electric and hydraulic sewer pipe rehabilitation robot systems, Pipetronics GmbH & Co. utilises two in-house CNC machining centres fitted with a wide range of BIG KAISER tools and tool holders that are available in the UK from Industrial Tooling Corporation (ITC). With headquarters in the South German town of Stutensee, Pipetronics uses the BIG KAISER range of products for the production of their robots’ turning and milling components. Founded in 2016 and currently employing around 100 people, the company offers a comprehensive portfolio of electric and hydraulic robots for modern sewer rehabilitation. “Currently, our robotic systems represent the most innovative, state-of-the-art technology in the field of sewer robotics, delivering maximum performance, return-on-investment and rugged durability for uncompromising daily use. A range of customised truck and trailer vehicle systems for trenchless sewer rehabilitation coupled with specialist pipe repair resins round out our offer,” describes Rolf Dettinger, Head of CNC Manufacturing at Pipetronics.

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Currently, our robotic systems represent the most innovative, state-of-theart technology in the field of sewer robotics, delivering maximum performance, returnon-investment and rugged durability for uncompromising daily use. Rolf Dettinger, Head of CNC Manufacturing at Pipetronics

Industry specialist in intelligent robotic pipe rehabilitation systems Pipetronics’ hydraulic and electric milling, filling and grouting sewer rehabilitation robots are characterised by their performance that delivers maximum reliability and work results even under extremely challenging work conditions. Retrofitted with an extensive set of milling, grinding and brushing attachments, these robot systems are equipped for the full range of sewer rehabilitation tasks. “The main function of these sewer milling robots is sewer rehabilitation preparation works on pipe liners and the opening of inlets after the liner has been set in place. Our milling robots take care of all the required work tasks, including the milling-off of edges, removal of stubborn deposits, repairs of sewer breakage points, damaged sleeves or even the milling of completely clogged sewers, all performed easily, safely and economically,” noted proudly Dettinger. To ensure the economically-efficient production of their robots, Pipetronics installed two in-house CNC production

Robotics

centres at its Stutensee facility. “Since we have relatively small batch runs, in 2019 we installed CNC machines to achieve faster, more flexible and economic production. Now, three years later, there’s no question that this was the right decision as we’re able to manufacture all our milled and turned parts economically with top quality - all in-house,” Dettinger praised this important step.

In-house CNC production To ensure complete coverage of all production processes, Pipetronics purchased a Grob G350 5-axis machining centre and a Mazak i400 ST turn/ mill centre. “Both of these machines were equipped with robotic handling functionality, which increased productivity and output, while simultaneously reducing our reliance on human labour.” “Currently, both machines run an average of 16 hours per day. We mill large parts on the Grob because it has a very long Z-axis. The Mazak is used to produce complex turned and milled parts,” Dettinger adds. To mill very close to the clamping device along the spindle, a slim, stable and precise tool holder is required and this is where the tool holder specialist BIG KAISER comes into the picture.

exceptionally high holding force, the Mega Double Power chuck is perfectly suited for high-chip-volume rough machining operations. Importantly, it is low maintenance, as it is perfectly sealed against coolant ingression and contamination. Thanks to the enlarged contact diameter on its clamping nut and tool flange, the Mega Double Power chuck achieves a holding force of up to 3200N/m, whilst its high stability ensures vibration-free high-performance machining operation.” Seeing the impressive results during the test phase, the CNC production manager was so impressed that he ordered several Micro collet chucks from the Mega Chuck series for the Mazak machine in addition to the tested power chuck. “The Mazak has a CAPTO C6 machine interface, which is ideal for turn/mill operations. For our application, the

BIG Micro Chuck collet chucks offer optimal performance characteristics for machining hard-to-reach workpiece areas, where conventional collet systems fail to deliver. Thanks to its groovefree collet nut, vibration at high speeds are prevented. The key is that this BIG KAISER micro collet system is slim enough to implement in all our machining operations. We mill at 12,000rpm on the Mazak and all BIG KAISER collet chucks have a guaranteed runout of less than 0.001mm at the collet mouth. That’s why we chose the slim Mega Micro Chuck. Initially available in only one size, we now run our Micro Chucks in a wide variety of lengths and diameters,” explains Dettinger. “Our cooperation with BIG KAISER has delivered excellent results. We currently produce over 890 different parts on our machines. The tool holders from BIG KAISER make our processes faster, more flexible and reliable, whilst being more cost-effective,” Rolf Dettinger concludes. Christian David adds: “We cannot stress enough how pleased we are with our BIG KAISER spindle tools. The power chucks and collet chucks have made a significant contribution to the production of intelligent robots for the harshest of environments.”

BIG CAPTO tool holders “From my previous job, I have significant experience with BIG KAISER spindle tools and BIG DAISHOWA tool holders. After being repeatedly disappointed by the quality of the default chucks used on the Grob, I finally contacted BIG DAISHOWA, and they kindly provided us with the Mega Double Power Chuck for testing,” says Dettinger. Christian David, Key Account Manager at BIG DAISHOWA adds: “Thanks to its Manufacturing & Production Engineering Magazine

Technology

It’s the solution, not necessarily the technology Craig Whitehouse, Managing Director of Invar Integration, takes an objective view of problem solving within the warehouse. Warehouses have become busy fulfilment factories, where throughput and performance can determine business success or failure. Now, as costs rise and labour availability falls, many companies are turning to technology to alleviate the pressure points in warehousing processes in order to free up valuable human resources and drive productivity. But technology in itself is only part of the equation; those looking to adopt automation should consider their options fully, and very carefully, before arriving at a decision. For a prospective buyer it can be tempting to read a few articles, identify a technology that looks appropriate and simply approach a technology vendor directly. Of course, this may work out fine. However, there is the danger that the buyer may just see the technology rather than the solution required. It’s all too easy to be sold a system that may work okay, as a compromise, but doesn’t necessarily offer you the best result – perhaps, falling short on flexibility, scalability, performance at

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peak or overall value, to mention but a few possibilities. What is missing here is independent, informed thinking. Automation, with the plethora of technologies available, can offer a whole host of possible solutions to a range of warehouse processes – from goods-received, storage and order picking to packing, sorting and despatch. New technologies, such as Autonomous Mobile Robots (AMRs) combined with pick-to-light technology, have transformed good-to-person order processing in recent years, bringing highly flexible and scalable, low-Capex solutions within comfortable reach of small to medium size enterprises. But the choices are many and varied, which can be bewildering – making unbiased technical expertise an invaluable resource to tap into. Working with an independent integrator offers a number of advantages. First and foremost, being independent means that recommendations relating to technology and potential suppliers are unbiased, and are not determined by the need to sell a proprietary product. A good integrator with strong software capabilities can therefore bring together the very latest and most advanced technologies for the task, producing a best-in-class solution. Having in-depth knowledge and expertise in the field of advanced warehouse automation, helps too, of course. For instance, there are any number of suppliers of AMRs capable of handling cartons, however, they all have their own particular attributes and limitations. Understanding the technical specifications is essential. But important to know too is the purchaser’s priorities – is it price, space, reliability etc? The starting point for any automation project has to be a complete understanding of the aims and objectives of the business. What level of growth is the business expecting year-on-year – is it 20% or more? What financial resources are available for any

automation project? Limited capital may not preclude automation, as point solutions and scalable technology can be deployed in stages over time. More specifically, what problems are you trying to solve? Automation may be adopted for any number of reasons, such as: increasing capacity, reducing reliance on labour, overcoming space constraints, lowering costs, increasing storage density, speeding processes, introducing higher levels of accuracy or enhancing operational resilience. But where in the warehouse can technology be best applied in order to deliver the desired objectives? An independent systems integrator can help guide a business through this process, ultimately, figuring out what an optimum solution should look like and then finding the appropriate hardware to deliver against the set objectives. Critically, it’s this independence that enables the customer to have access to the very latest advanced technologies, a resource that can deliver the best-fit technology for their application. All in all, far better than taking a hardware first approach and then trying to crowbar the solution around it. Bringing a combination of technologies together in a cohesive way, based on process efficiency and overall performance, is what counts and much of this depends on the software development and the skills of the integrator to successfully tailor the solution for optimum performance. One of the biggest factors determining whether a solution works well or not is the software. That’s why it’s important to work with an independent systems integrator with its own inhouse developed software and control solutions. As an independent, full-spectrum automated warehouse solutions provider, Invar Group is free to select the most appropriate technology for the task, and being a multifaceted organisation that brings together skilled individuals with competencies across warehouse management software, systems integration and controls, we take responsibility for the complete turnkey-key system from start to finish. More on smart warehouse automation at www.invargroup.com

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Growth Keeps Coming at GM Group

High-profile sales and design appointments point Lesters towards £25m turnover target One of the packaging sector’s fastest growing companies is targeting further expansion after making two high-profile appointments. Lesters, which has seen revenues grow 120% over the last twelve months, has recruited industry experts Mark Furman and Greg Burton as Head of Sales and Design Manager respectively. The former has more than 33 years’ experience working in the industrial corrugated marketplace for blue-chip companies and is bringing his knowledge, processes and experience to support the Burntwood firm’s desire to hit £25m by 2025. He will also be tasked with aligning state-of-the-art design and manufacturing capabilities with the group’s in-house warehousing and logistics operations, providing a seamless solution for clients

in the aerospace, automotive, bike manufacturing, mail order and third-party logistics space. It has been a whirlwind period for Lesters over the last two years, with fifteen staff taken on across production and in admin/support, whilst a second shift has been introduced to keep up with demand. This has helped support the design and manufacture of a growing range of products, including octabins, pallet boxes, heavy duty packaging, bespoke die cut units, corrugated cartons and retail ready packaging. The ‘large packaging’ specialist is also keen to innovate the materials it uses, as well as looking for new applications outside the world of packaging. For further information, please visit www. lesterspackaging.co.uk

ITC Employs With New Sales Engineer Ongoing expansion at Industrial Tooling Corporation (ITC) has now seen the Tamworth cutting tool manufacturer add a new Technical Sales Engineer to its ever-expanding team. As the UK’s leading cutting tool manufacturer, ITC has continually strengthened its infrastructure with an expanded product portfolio, enhanced

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Following a remarkably successful debut at the MACH exhibition, the GM Group has further expanded its team by appointing a new Area Sales Manager for the South of the UK. Joining the Oldham-based machine tool specialist, Andrew Yeomans is a seasoned engineer with more than 35 years in the industry. The new appointment will target sales of the Victor CNC portfolio and build brand and market awareness in the Southern counties. As the UK’s exclusive distributor for the Victor CNC machine tools, the GM Group has witnessed significant growth, which more than justifies both the company’s recruitment drive and the investment in a new

service, support, re-grind and bespoke tooling offering. As the company expands, it has continually added more technical sales engineers to evolve its unparalleled levels of customer service and support. The appointment of Ben Morgan as a Technical Sales Engineer will bolster the support provided to manufacturing companies in the Southern region of the UK. The restructuring of the Southern territory will see Ben Morgan support manufacturers in the South, predominantly the Oxfordshire, Berkshire and Hampshire areas with Luke Insley working with customers

facility that is planned for completion this Autumn. The company is investing heavily in its factory expansion, new staff and infrastructure investment to enhance customer service, support and sales. Starting his career as a mechanical engineering apprentice in the late 1980s, Andrew followed his comprehensive apprenticeship programme in several roles as a CNC machinist before progressing to a team leader position at the prestigious Westwind Air Bearings facility in Poole. Following a successful period at Westwind, Andrew spent the next decade as a technical sales engineer with several world-leading cutting tool manufacturers. In 2011, the experienced engineer moved into machine tool sales, spending the last 10 years supporting all types of businesses from small subcontract job shops to OEMs in all industry sectors, identifying and meeting the needs of manufacturers with tailored machine tool solutions – from consultation and sales through to training and commissioning.

in the South East, the two engineers will fill the role left by longstanding employee Dave Cleeve. Ben entered the industry as an engineering apprentice in 2011, learning his trade as a multi-axis programmer and machinist in the aerospace industry. The new ITC engineer undertook a comprehensive apprenticeship that encompassed everything from machining and programming to PC-DMIS inspection, CAD, CAM and CNC programming and much more. Rapidly rising through the ranks, Ben progressed to team leader, before moving to another prestigious manufacturing company and subsequently joining ITC.

People On The Move British Water appoints Mark Fletcher as chair Mark Fletcher, global water leader at Arup and an Arup Fellow, has been announced as British Water’s new chair. The appointment was announced at the trade association’s annual general meeting on 28 July 2022 and comes as Chris Loughlin steps down from the role. Fletcher joined the British Water non-executive board in 2020 and is

Leading Life Safety manufacturer Hochiki Europe invest in their people to ensure the best for their customers Hochiki will be making significant new investments in their people to support the Middle East, Africa, and European regions in order to develop the expertise they can bring to their customers in 2022 and beyond. Accomplished Mr Shinsuke Kubo, Hochiki’s Managing Director for the Middle East operation based out of Dubai, has been recognised by both customers and the business’ internal teams as a shining light when it comes to customer experience. With his extensive knowledge of both the Hochiki product and the fire industry, he will now take up the role of Commercial Director for Hochiki Europe, Middle East, Africa, and India. This new role will be based out of the UK head office in Gillingham, Kent, with regular visits to the Middle East, where Kubo will continue to play a key role in the strategic development of this region and remain as a board Director.

Using his vast experience of the market, in this new role, Kubo will be focused on leading the product management team to develop the company’s road map to ensure it meets the needs of customers. With a desire for an efficient operation, he has already set up his key team with David Brown as Product Manager and Robert Head as Commercial Product Manager, who between them bring over 40 years’ experience of working with Hochiki and within fire safety. A crucial element to this new role and indeed the team will be the close working partnership between them and the teams in Japan and of course the Research and Development arm of the business. The constant feedback between customers, Japan and R&D teams will enable Kubo to realise his ambition to take Hochiki to the next level for its customers. Both Graham Lowe, Hochiki Europe’s Managing Director and Kubo’s priority throughout this transition and beyond is to ensure that customers continue to receive the absolute best service and products from Hochiki, therefore Shahab Anjum Head of Sales Middle East and his team will continue to support in developing Hochiki’s sales within the region. To find out more about Hochiki Europe and its range of market leading life safety products visit hochikieurope.com

former chair of the Water Industry Forum, which merged with the organisation in April 2022. He has over 35 years’ experience working across water in the UK and globally. An international authority on urban water resilience, Fletcher was made an Honorary Fellow of CIWEM in March 2021, a Royal Academy of Engineering (RAEng) Fellow in 2019 and an Honorary Fellow of the Society for the Environment in June 2018. He has worked on the City Water Resilience Approach, developed to help cities grow their capacity to both anticipate and mitigate water-related shocks and stresses. Fletcher was also faculty leader for the Arup University - Massachusetts Institute of Technology Sloan Business School course, Resilience of Urban Systems from 2017 to 2020.

Siemens appoints Sarah Black-Smith as General Manager for its UK Motion Control business Siemens has appointed Sarah Black-Smith as General Manager of its Motion Control business in the UK. Sarah takes on the role after a successful run as Head of Factory Operations at Siemens’ Congleton factory where she was responsible for all production, lean operations and the Engineering teams. The appointment further underlines Siemens’ commitment to strengthening gender equality across the organisation and its drive to increase the number of women in engineering. In 2021 half of graduates and 42% of intern recruits were women. Sarah’s career with Siemens spans almost 20 years. She holds a BEng in Manufacturing Engineering and Management from Loughborough University and an MSc in Operations Excellence from Cranfield University. Sarah was in a placement at Alstom Power when it was sold to Siemens in 2003. Siemens then sponsored Sarah’s final year, taking her on as a young graduate joining as a Lean Implementer in Lincoln in 2004 progressing to Manufacturing Manager in 2010.

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Game-changing intralogistics technologies at IMHX 2022 Sales of autonomous mobile robots and driverless lift trucks are taking off but the game-changing intralogistics technologies we will see at IMHX 2022 go much further than the simple replacement of man by machine, says event director, Rob Fisher Across the intralogistics sector sales of autonomous mobile robots (AMRs) are booming. Indeed, in a recent report Interact Analysis forecast that more than 1.1 million robots will be deployed in warehouses around the world before the end of 2024. And almost a fifth of respondents quizzed earlier this year for the IMHX Optimism Index expected to be using AMRs to some extent within the next 12 months - a remarkably high figure for a technology that was seen as futuristic just a few years ago. In simple terms, AMR technology differs from the science behind longestablished Automated Guided Vehicles (AGVs) in that the units do not rely on human interaction to change route. Instead, on-board navigation systems guide them between destinations. These robots are proving a particularly effective alternative to the type of conveyor-based sortation systems that have historically been used at parcel hubs and order fulfilment centres. Their attraction is partly based on the fact that they require a significantly smaller floor area within which to operate than a conveyor to achieve the same parcel throughput statistics - at a time when every square foot of available floorspace has to be

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optimised, this particular benefit is clearly a significant plus point. Modular AMR-based sortation systems are also scalable, so additional robots can be introduced as and when they are needed to cope with any spikes in throughput and, what’s more, if an individual robot malfunctions, it is simply and quickly removed from the ‘shop floor’ and replaced with no discernible drop in throughput capacity. The technology is also fully portable, which allows systems to be switched between sites if required. Until now China and the USA have been the top two investors in AMR sortation systems but, as autonomous mobile robot technology’s reputation for bringing flexibility and scalability to some of the busiest parcel sorting hubs in the world spreads, Europe’s logistics community is increasingly conscious of the benefits that this innovative, low CapEx approach brings. Of course, other forms of robotic and automated intralogistics technology are taking off too. For example, with a substantial decline in the availability of forklift drivers recognised as a major problem, a growing number of warehouse and distribution centre operators see driverless forklift truck technology as the solution to the recruitment and employment cost challenges they face. Driverless forklifts undertake every type of task that would be expected of a manually-operated forklift – including vehicle loading and unloading, pallet put-away and retrieval in both

standard and very narrow aisle racking configurations, as well as pallet and stillage movements throughout the warehouse. In addition to the obvious savings in labour costs that driverless forklifts bring, other benefits include: reduced damage to goods, racking and trucks; greater picking accuracy; and more efficient use of the available storage space. DHL and Walmart are among the high profile businesses to have already adopted driverless lift trucks, while countless small and medium sized forklift users are also benefiting from the advantages that the technology delivers. But the developments and technologies we will see at IMHX 2022 will go much further than the simple replacement of man by machine. Artificial Intelligence, machine learning, ‘big data’ and the Internet of Things are beginning to be adopted in a significant way right across the logistics field to allow warehouses or distribution centres to become self-learning, selfcorrecting, self-optimising operations capable of adapting to change in real time. And as technology continues to play an ever-more crucial role in shaping the future of supply chains, IMHX 2022 will provide a fascinating opportunity to discover artificial intelligence, robotics, and automated handling systems by bringing together world-class suppliers of intralogistics and supply chain solutions across three days of interactive demonstrations, exciting new product announcements and immersive experiences. In addition to the full exhibition floor, which includes names such as Whittan Group, Knapp, Combilift, Geekplus, Cesab, Zebra Technologies and Swisslog, IMHX 2022 will also host a multi-track series of educational seminars, talks and workshops. Covering key industry themes and trends, the line up of influencers, innovators and pioneers among the conference speakers will reflect the growing role of artificial intelligence, automation and robotics within the modern supply chain. The seminars are free to attend and alongside the innovations on show within the main exhibition halls they make a day at IMHX 2022 an outstanding opportunity for logistics industry professionals to stay ahead of the shifting landscape of supply chain processes. IMHX 2022 takes place from 6 – 8 September at the NEC, Birmingham. To find out more and activate your free pass, please visit imhx.net.

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Waste & Waste Control Siemens’ automation and measurement technology keeps Plastic Energy’s plants recycling Chemical recycling leader transforms end-of-life plastic waste into recycled oil to produce new products

A pioneering partnership between Siemens and global chemical recycling expert Plastic Energy is helping divert plastic waste from landfills and incineration.

mechanically recycled, such as films and flexibles. Plastic Energy developed a TAC™ recycling process, which converts plastic waste into a valuable substance called TACOIL™, which serves as a feedstock to produce new plastics. TACOIL™ has been incorporated into more than 10 products and packaging on the European market from brands such as Unilever, Tupperware and L’OCCITANE en Provence.

Plastic Energy is innovating the plastic waste landscape with a recycling process which transforms end-of-life plastics into recycled oils that can be used to make new plastic products such as food-grade packaging. The patented technology is currently used in two plants in Spain where Siemens’ automation and measurement technology, including SIMATIC PCS 7 and COMOS MRO, ensure the smooth running of control systems and overcomes the challenge of a complex mix of material consistency.

Through Plastic Energy’s processing, plastic waste becomes a resource itself, with dedicated procedures for recycling that tackle the global challenges of disposal and benefit the circular economy.

Now, to meet growing demand for plastic recycling, Plastic Energy is building several larger facilities across Europe, Asia and the US, starting with one in The Netherlands with partner SABIC. These plants will be significantly upscaled and feature Siemens’ end-to-end technology solutions, including Distributed Control Systems (DCS), process instrumentation and low voltage switchgear in the form of SIVACON S8 technology.

Carlos Monreal, CEO at Plastic Energy, headquartered in London, said: “Through our unique and patented technology and our long-proven process we achieve two important results: we prevent depletion of natural resources while simultaneously diverting plastics from incineration and landfill, thus protecting the environment from plastic pollution by decreasing the volume of end-of-life plastic waste that could end up as plastic pollution.

The long-term collaboration will enable Plastic Energy to continually evolve its technology and process, implementing improvements for better efficiencies and product quality, and achieve flexibility and scalability for its plant designs. Steve Leech

Plastic Energy’s goal is to recycle five million tonnes of plastic waste by 2030.

Plastic Energy is also working with Siemens to unlock further potential using a digital twin. This powerful tool creates a virtual model to give better insights and closed loop optimisation of both process and plant performance. Steve Leech, Business Manager for Siemens Process Control Systems, said: “We have viewed working with Plastic Energy as a long-term partnership from the beginning of our relationship, which brings together the process and industry knowledge of Plastic Energy, with our innovative technology portfolio. The result is a process plant that is flexible and provides the opportunity for value-add use of the data provided, through using SIMATIC PCS 7 and our instrumentation platforms. It is great to be involved with a company so focused on sustainability and contributing to a positive impact on the environment through recycling of plastic waste.” The durability of plastics creates a serious problem for the environment. Roughly one-third of the world’s plastic packaging waste ends up in the oceans or in unmanaged dumps on land. Meanwhile, more than 50 percent of collected plastics end up in landfill, or incinerated, meaning valuable resources are disposed of in unsustainable ways. Then there is the challenge of what to do with the plastic waste that cannot be

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“Utilising Siemens automation and processing software is important to ensure that our recycling plants are operating to their full potential, and that we are able to continue to recycle as much plastic waste as possible.” Carlos Monreal

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