Jaymie Phillips, lecturer at MADE Cymru & University of Wales Trinity Saint David
From meticulous planning through to production and assembly, UK manufacturing processes are a key factor in our reputation for excellence. But as technology and processes evolve, our continued manufacturing success will depend on a willingness to embrace new opportunities.
The latest developments in manufacturing technologies are commonly referred to as Industry 4.0. From shiny autonomous machines to sentient air fresheners, the scope of Industry 4.0 is vast, with debate over which technologies and processes the term describes.
One common theme of Industry 4.0 involves using technology to manage parts of the manufacturing process without human intervention. Yet this idea reflects only a small portion of the possibilities offered by Industry 4.0.
Understandably, many organisations want to implement the newest Industry 4.0 technologies to improve efficiency and maintain an edge over the competition. But without the right knowledge of which technologies to invest in, manufacturers can end up wasting money on expensive equipment without improving efficiency in their specific production processes.
Understandably, many organisations want to implement the newest Industry 4.0 technologies to improve efficiency and maintain an edge over the competition. But without the right knowledge of which technologies to invest in, manufacturers can end up wasting money on expensive equipment without improving efficiency in their specific production processes.
Only by having a clear and holistic understanding of the operations and tasks that make up the production process can manufacturers reap the rewards of Industry 4.0. In other words, companies need to know which inefficiencies exist within their production processes before exploring how Industry 4.0 technologies could solve them.
A Typical Development Project
Let’s consider an organisation that might benefit from adopting Industry 4.0 technology.
A company that manufactures illuminated key fobs relies on processes like moulding raw materials, soldering electronic components and assembling final products. Much of this process can be automated using Industry 4.0 technology. What’s more, waste can be reduced by using lean manufacturing, which we consider as a key underlying principle of Industry 4.0. If the company wants to expand its product range and increase output while reducing inefficiency and waste, Industry 4.0 technologies could be the answer.
A leading machine manufacturer has developed a machine that can perform all the tasks that are currently undertaken by the key fob company, while also brewing coffee and identifying wildlife. It seems like an ideal solution. Yet the equipment costs £500k, leaving the key fob company in a predicament. Should they replace their current processes with one machine, or use the money to fund development of an alternative solution?
It may be an oversimplification, but this scenario reflects the choices faced by real organisations within a constantly moving landscape of technology and competition.
An Alternative Solution
Purchasing something new is always exciting. But when a solution to a problem can be bought, it doesn’t always mean it’s the best option.
In the oversimplified example above, the key fob company wouldn’t need all the functions offered by the proposed machine – an ability to identify wildlife wouldn’t be remotely useful in their manufacturing process. Exploring which functions would most benefit the organisation would be a far better approach, eliminating the need for expensive features that add no value to the production process.
With such a wide variety of advanced and flexible technology available, it’s possible to develop processes that are bespoke to the needs of a given organisation. This is where true innovation can be achieved through Industry 4.0. With a little problem solving and creative thinking, useful functions can be added without spending unnecessarily large amounts of money. Organisations can benefit from greater flexibility in the solutions they implement, while taking real ownership of the technology they invest in.
Implementing a custom solution like this allows for a great degree of freedom, yet there are still challenges that need to be overcome. Despite the wide availability of Industry 4.0 technologies, manufacturers aren’t always equipped with the skills needed to implement them efficiently in specific applications.
What’s needed first is a complete understanding of the tasks within the production process, so that the best possible solution can be developed. This understanding should then be complemented with the skills needed to implement such solutions.
MADE Cymru, a suite of projects and programmes offered by University of Wales Trinity Saint David, has been specifically designed to satisfy this need.
We’ve incorporated Industry 4.0 principles and skills into our programmes, upskilling engineers and manufacturers to find and implement the right solutions for the production processes they’re involved with.
This means participants in our programmes don’t simply consider which shiny and expensive new tool can perform the tasks required. Instead, they choose the best-suited and most efficient technology for the process, considering the changing demands and opportunities of modern industry to come up with sustainable and innovative solutions.
This article is taken from a series of webinars in a three-day industry summit organised by MADE Cymru and University of Wales Trinity Saint David (UWTSD) in June 2021. MADE Cymru is an EU funded (via Welsh Government) initiative that seeks to support and boost manufacturers in Wales via upskilling programmes and R&D. Find out more www.madecymru.co.uk or email one of the team at [email protected]