Andrew recently worked as a Development Moulding Engineer, managing the build of moulding cells including vendor selection, project management, process development and validation.
Prior to this, Andrew spent 9 years working for major injection moulding machine suppliers as a Service Engineer, later moving into applications and project management after serving his apprenticeship in electrical engineering and electronics.
With Dublin based Invotek Polymer Solutions, Andrew aims to leverage his 23 years experience within the plastics industry to provide solutions and help customers navigate complex challenges, improve efficiency and achieve operational success with his portfolio of Motan Colortronic, Regloplas, Reglochill, Sesotec and Herbold Meckesheim.
As Sumitomo (SHI) Demag celebrates 50 years of market presence in the UK and Ireland, the team examine the most important chapters that have helped to shape the industry as we now know it. Including the company launches and events that align to the most important engineering and manufacturing eras in modern history.
Having turned 50 in September, Dave Raine, Nigel Flowers and the team reflect on some of their favourite company moments, encapsulating them into 5 distinctive eras. Including revealing the number one topic flagged at the company’s very first Board Meeting hosted by MD Barry Taylor in Leighton Buzzard on 2nd October, 1974. And why, thanks to Service 3000, digitalisation is anything but a new concept at the forward thinking company
The Heritage Era
Demag Hamilton was formed at the end of September 1974 when Hamilton Machinery combined with Demag AG. At that time, the total market of British built and imported machines was 2,700. There are now over 5,800 companies in the UK plastics industry, operating almost 16,000 machines and contributing £25 billion annually to our economy.
But the history of company in fact predates 1974. Several decades before establishing its presence in the UK and Ireland, Demag had already made a name for itself as an innovator on the continent. Responding to high demand for inexpensive, mass-produced plastic products after the war, Demag Plastics Group (Ankerwerk Nürnberg) manufactured the world’s first reciprocating screw injection moulding machine. This was in the 1950s. A time when manufacturers in all sectors switched from producing metal components to plastic components.
In 1956, Ankerwerk then engineered the world’s first single-screw injection moulding machine, giving more precise control over the speed of injection and enabling materials to be mixed before injection.As agents of Ankerwerk and trading as Hamilton Machinery Sales, the UK company’s first machine was this very machine. And it was installed by British Geon (now BP) of South Wales in 1957.
One year before launching Demag Hamilton, the team in Germany launched the first injection moulding machine employing a digital hydraulic system. It resulted in faster set ups and greater consistency and processing precision over periods of time. “This technology was very much the precursor to the drives we see today. The main difference is the relative efficiency – including energy consumption – and the high repeatability of a digital system. From those very early days (and even before as the UK agent), we’ve been at the forefront of addressing production challenges, whether it’s fast cycling, new technologies or energy consumption,” notes Director Nigel Flowers.
The minutes of those early meetings show that despite 50 years passing – the same market challenges endure. In that first board report, uncovered in the archives, MD Barry Taylor “expressed concern at the continued uncertainty over the UK market.”
In 2012, the company rebranded as Sumitomo (SHI) Demag.
The Support Era
Back in the early days, there were no mobiles, pagers or computers. Nigel’s first job as a service engineer in 1986 involved travelling in the company Ford Sierra 1.6L Estate to IMED in Letterkenny Ireland to fit a number of machines with robot interfaces. “It was January, West Coast of Ireland and bit grim weather-wise. On the plus side I had 15p-a-day luncheon vouchers!”
Articles published by PRW reveals that in 1974 Demag Hamilton employed 10 service engineers with a charge out rate of £3.50 p/h. You may balk, but that was 50p lower than the hourly charge recommended by the PMDA. A responsive service was as important then as it is now, and the company was managing more than 800 Ankerwerk and Stubbe machines – many of which were built in the company’s factory in Craigavon Northern Ireland.
Testament to the longevity of a well-serviced machine, SDUK recently discovered that the Athlone Technology Institute is home to one of the original Craigavon machines. There are murmurings that this slice of manufacturing history will soon be relocated to the Limerick facility. Dave hopes to invite every customer that has used this machine over the years for training to view it in its new location.
Service has always been a critical company differentiator. The UK team was the first to introduce annual machine “check-ups” in 1996. The D-Check evolved into the ErgoCheck, which is now accompanied by activeCare.
A standardised test, the D-Check helped customers ensure their machine was still operating in accordance with the original manufacturer’s protocols and design performance. It later developed into activeCare, where we offered enhanced value to customers by not only checking performance but also changing wear components.
Fifty years on and we are fully immersed in the era of datasets and remote diagnostics. Technical Manager Nick Stockton, who joined the company as an apprentice in 1999, reflects on how important modern connectivity is now for processors and why digitalisation is anything but new.
Sumitomo (SHI) Demag has been building digital datasets for over 25 years. It just didn’t go by the same name. Service 3000 was introduced in 1996 to investigate service pinch points. It generated monthly data reports. So not really real-time. But nonetheless, it was an extremely valuable piece of research to support decision making
“The benefits of digital technologies and dashboards that are now deployed today are incomparable to the days of trying to decipher processing issues when an engineer is calling from a phone box on the road, without being able to see what was happening on the machine,” comments Nick.
The Debut Era
As pioneers of all-electric injection moulding machines and driven by the emerging sustainability agenda, the first SE series was unveiled the same year that Sinead O’Connor’s Nothing Compares 2 U topped the Billboard charts. Towards the end of the decade, fast cycling became a reality with the introduction of modular drive technology on a hybrid El-Exis S high-speed machine.
Setting another trend, the IntElect with water-cooled direct drives for all movement axes launched in 2003. This was designed to meet very specific clean room requirements commonplace in the medical sector. “This represented a move into direct drive, all-electric presses, which until then had mostly been confined to Japan,” observes Nigel
But it was the debut of the DEMAG Ergotech EXTRA machine, also in 2003, that really rocked the market recalls current Managing Director Dave Raine. “This was, by far, our fastest selling and most popular German built machine. For £23,500, processors could get all the additional productivity-enhancing and reliability features that would have usually cost them more. It was a step change in the company’s R&D to ensure that productivity features were no longer a nice-to-have.”
This year, the company launched an IntElect equivalent to the EXTRA. Giving customers a fast-delivery, energy efficient and fast cycling model, without the need for customised features, SDUK recently sold its first IntElect EXTRA to a customer in Ireland.
The Ireland Era
Craigavon can be defined as one of the company’s biggest success stories. In 1974, PRW reported that since starting production of the Stubbe machines in 1967, the production space more than doubled. In seven years, 800 Stubbe injection moulding machines were delivered to customers in Britain and Eire, as well as further afield. Christoph Fischer, GM at that time, was awarded an MBE for his services to industry as result of the success of the Craigavon plant.
Being so deeply rooted in Ireland’s plastics processing sector is often underplayed, reports Dave. But with more than 400+ supported precision machines manufacturing billions of medical, biotech, electronic, automotive, engineering and FMCG packaging components yearly, the company last year opened a Centre of Excellence in Limerick. This now provides customers with direct access to IOM3-accredited training, and a dedicated team of experienced technical, service support and processing professionals.
“Given the maturity of the precision processing market in Ireland, our new Ireland office provides us with the opportunity to serve our customers in the best way possible while building upon our physical footprint in the region,” adds Dave.
The Productivity Era
Last decade the buzz words were sustainability and energy efficiency. Now, productivity is the golden ticket and what every processor is seeking to optimise. Having surpassed 85,000 IntElect global installations in 2022, the Group continue to invest in R&D to unlock efficiency improvements, reduce material waste and address labour shortages
“It’s widely considered a ‘given’ that energy efficiency and reduced pollution are the benefits of all-electric injection moulding machines. Especially in today’s eco-conscious manufacturing world. However, beneath the hood of our IntElect machines are a number of velocity and injection power features that, when used correctly and repeatably by moulding operatives, result in faster cycle times and more stable start-ups. Even before any process optimisation steps have been introduced and expert setting knowledge has been imparted,” exclaims the newest team member and Area Sales Manager Ashlee Gough.
Field tests, combined the with 2024 Productivity roadshow, have been instrumental in helping our customers to identify and introduce further process improvements, notes Ashlee. “For productivity to be sustained, marginal gains is the best approach. Every incremental improvement boosts productivity that little bit more. Providing polymer manufacturers with greater capacity to take on new customers and more projects.”
For the entire team, it’s this attention to detail that ensures customers will continue to remain the strongest advocates of Sumitomo (SHI) Demag machines.
Since the early days, the company has changed beyond all recognition. But our enduring values, service approach, and people focus remains as strong today as ever, asserts Nigel. “As we reflect on everything accomplished, I’d like to thank each and every one of our 400 customers spanning the automotive, IT, packaging, electronic, medical and pharmaceutical, building products and leisure industries for sharing this exciting journey with us to greater productivity.”
One of the first Ankerwerk machines sold by UK agent Hamilton Machinery Sales was installed by British Geon (now BP) of South Wales in 1957.
These original artworks were commissioned in 1994 to showcase the technological evolution of Demag, which was rebranded Sumitomo (SHI) Demag in 2012.
Field tests, combined the with 2024 Productivity roadshow, have been instrumental in helping customers to identify and introduce further process improvements.
SDUK MD Dave Raine (L) and former MD Nigel Flowers (C) were joined by two past Group CEOs Dr Tetsuya Okamura and Gerd Liebig, and former CFO Shaun Dean (R) to look back and mark the significant milestone.
At this year’s Fakuma, the German plant manufacturer GETECHA will be presenting its comprehensive range of services for the realization of automated size reduction solutions for the plastics and recycling industry. In Hall A3, the company will be showcasing numerous exhibits demonstrating how users of injection molding, extrusion, thermoforming and blow molding technology can grind and reuse their production waste efficiently and in a resource-saving manner. As a special highlight, the company will be presenting its new RS 150 compact granulator, which is tailored to the grinding of sprues directly at the injection molding machine.
Plastics processors, recycling experts and recyclate manufacturers who are looking for competent partners for modern grinding technology projects at Fakuma should plan a visit to stand 3210 in hall A3. This is where plant manufacturer GETECHA will be presenting a wide range of machines and services for the realization of automated system solutions for the efficient grinding of waste, offcuts and residues from production. The focus will be on various hopper granulators, flexible feed and discharge technology and, last but not least, all the engineering expertise with which the company knows how to master even the most challenging tasks. Another highlight of GETECHA’s appearance at this year’s Fakuma is the presentation of the new RS 150 granulator, which is tailor-made for direct use in injection molding technology lines. “This compact granulator is a cost-effective and versatile all-rounder for the production-integrated grinding of sprues and light faulty parts. It guarantees excellent regrind quality even when processing TPE and POM, scores points for its low energy consumption and takes up very little space thanks to its envelope dimensions of 674 x 435 x 775 mm. It also requires minimal maintenance,” says Eva Rosenberger, Sales Manager and Shareholder at GETECHA.
Efficient, compact and flexible
The new RS 150 is a hopper model for manual or automated material feeding via the handling systems of injection molding machines. It can be adapted to feed heights of around 775 to 1,280 mm, has a powerful three-blade rotor in a horizontal design and is prepared for connection to a vacuum extraction system provided by the customer. The design allows flexible adaptation to different production conditions. For example, the rotor variants, drives and blade qualities can be designed specifically for each case and the hopper can be designed for feeding by sprue picker or manual feeding. Intervention protection is ensured from a low feed height of 775 mm and, depending on customer requirements, the new RS 150 is available with a low or high frame. “A fill level sensor prevents the material box from overfilling, so that material cannot back up into the cutting chamber. Optionally, a warning signal can be issued or a hopper loader can be activated so that the production process always remains stable,” explains Eva Rosenberger. As an option, GETECHA can equip the new beside-the-press granulator with modern sensor technology that records the capacity utilization and consumption in the context of an overall system and allows the system to react in a targeted manner in order to reduce consumption and release the system’s operating reserves.
Wear-resistant for abrasive materials
In addition to the new RS 150, GETECHA will be exhibiting several granulator models at Fakuma that prove themselves day after day in many areas of plastics and recycling technology. For example, the GRS 180 series of granulators, whose application is also grinding of sprues and faulty parts from injection molding technology. The hopper version is also suitable for manual or automatic feeding via the handling system. The GRS 180 system has optional wear protection plates in the hopper so that it is also suitable for abrasive material in combination with the wear-protected hard metal blades of its seven-blade rotor. An optional water-cooled cutting chamber reduces the thermal load on the material to be ground and prevents it from plasticizing in the cutting chamber. The rated power here is 2.2 kW and is effectively reduced to around 1.1 kW under load by using the GETECHA EnergySave system. “We also offer a screw feeder for positioning under the injecting molding machine and a sluice hopper for productions with increased cleanliness requirements,” explains Eva Rosenberger.
Designed for higher hourly throughput
For plastics processors and recyclers with higher demands on size reduction technology, GETECHA will be exhibiting a GRS 300 A at its Fakuma stand, with a higher frame and moved on rollers for free regrind discharge into a collecting container. It can be used as a small central granulator or a large beside press granulator for grinding sprues and faulty parts. The inclined ten-blade rotor of this granulator, driven by a 5.5 kW motor, allows the system to be started up even when partially filled. At rotor speeds of 230 rpm and depending on the type of plastic and screen perforation, its wear-protected blades (HSS quality) grind up to 80 kg of material per hour. And as Eva Rosenberger emphasizes, “this granulator also scores with easy cleaning and tool-free screen changes”.
The RS 2404 A, which GETECHA will show at Fakuma, is designed for an hourly grinding capacity of up to 160 kg of material. This movable compact central granulator has a cutting chamber and a feed hopper in a double-walled, sound-insulated design. The parts will be feeding by hand or by conveyor belt and grinded by an open three-blade rotor with attached blades (drive power 5.5 kW). The granulator can be seen at the fair with an integrated extraction system, sound-insulated conveying fan, exhaust air dedusting unit and the GETECHA GE 12 regrind dedusting system.
As the largest model in its comprehensive range of granulators, GETECHA will be presenting an RS 38060 A for the efficient size reduction of blow-molded containers and injection-molded parts at this year’s Fakuma. This central granulator, which is driven by a 22 kW motor, is a universally applicable system that is designed to process containers and tops and tails of up to 60 dm³ in size. The feeding hopper is generously dimensioned and its design is very easy to maintain: the screen carriage runs on rollers and can be complete and easily extended without tools. “Other plus points of the granulator include the optimally tuned rotor and the hand hydraulics for easy opening of the hopper,” says Eva Rosenberger.
Analysis and integration
Overall, GETECHA’s current service catalog offers modern grinding technology for volumes from 10 to 5,000 kg/h. All of the company’s granulators are characterized by a design that has been thought through down to the last detail, can be customized and enables low-maintenance, energy-efficient operation. The high level of consulting expertise of the plant manufacturer includes the analysis of the individual application and the integration of the grinding solution into the customer’s infrastructure, which usually opens up additional savings and optimization potential. All GETECHA grinding systems can be automatically controlled and integrated into the customer’s IT infrastructure.
A highlight of GETECHA’s appearance at this year’s Fakuma is the presentation of the new RS 150 granulator, which is tailor-made for direct use in injection moulding lines.
Eva Rosenberger “Our new compact RS 150 beside-the-press granulator is a cost-effective, versatile all-rounder for the production-integrated grinding of sprues and light faulty parts. It guarantees excellent regrind quality even when processing TPE and POM and scores points with its low energy consumption.” (In the picture a GRS 300.)
The GRS 180 A beside-the-press granulator from GETECHA has wear protection plates in the hopper so that it can also cope with abrasive material in conjunction with the wear-protected carbide blades of its seven-blade rotor.
On the GRS 300 A GETECHA – shown here in the open state – the inclined ten-blade rotor driven by a 5.5 kW motor allows the system to start up even when partially filled.
Sumitomo (SHI) Demag has launched a new digital feature integrated into the company’s IntElect 2 series. Automatically adapting to the injection moulding process, activeMeltControl can compensate for melt viscosity variations in nearly all applications and materials, including recycled plastics. Resulting in significantly reduced reject rates.
Recently unveiled at the company’s European roadshow, activeMeltControl (aMC) has been described as a game changing feature by material and processing experts. Automatically adapting to the injection moulding process, aMC continually monitors for variations in holding pressure and switch over position. Once a parameter is identified as drifting towards the tolerance limits that have been set by the user, aMC automatically amends the set parameters to compensate for the variation. The adjustment bandwidth is also defined by the processor.
The background for this development, which Sumitomo (SHI) Demag has vigorously pursued over the past four years, is driven by changing quality of plastics due to fewer virgin materials and more recyclable content. “Many customers have requested a digital solution to compensate for these variations when manufacturing precision parts using our highly efficient all-electric machines. That’s why we introduced aMC as a completely independent software module that complements our established active modules,” explains the company’s Product Manager for Digital Solutions, Dr. Thomas Schilling.
“With aMC, we can now automatically adapt to melt viscosity variations in nearly all applications and materials. These variations may be due to batch fluctuations, recyclables, regrind, drying differences, dosing variations, or the use of additional additives,” highlights Area Sales Manager Ashlee Gough. For example, variations in the melt flow index (MFI) in 100% recycled material can now be corrected by the software. Meaning that the process stability is now comparable to a process that uses virgin material.
This offers processors greater manufacturing flexibility, allowing for the use of a broader range of post-consumer and post-industrial recycled material types. Even customers with defined processing references benefit, as aMC instantly addresses any variability to maintain absolute processing precision and stability.
“Some of the challenges of running a reprocessed material in comparison to a virgin polymer material is these need to be manually adapted and played with during processing. The introduction of technologies like aMC allows processors to monitor the melt flow of material throughout a batch which enables adjustments to be made automatically rather than being manually controlled by a setter,” notes Isy Ferguson, Managing Director at Hardie Polymers
Another advantage of aMC is it only sets the limits for holding pressure and switch over position. This means it can be used in all industries, including those where there are defined tolerances for validated process parameters that cannot be exceeded or overridden by machine operators. “In terms of production stability, this innovation can make a big difference to productivity and processing continuity,” assures Ashlee.
Achieving more consistent part weights within a processing batch means that the ROI can be exceptionally fast, claims Gough. Additional benefits include better process consistency, longer machine uptime, and reduced scrap. All of which contribute to greater productivity and sustainability.
Activated with a single click, aMC is a fully automated control process that is integrated into the Sumitomo (SHI) Demag IntElect machine’s control system. It is available as an optional extra on company’s newest IntElect 2 machine series. It can also be retrofitted to older IntElect 2 machines too.
The new activeMeltControl feature Is now available to UK and Ireland customers with IntElect 2 machines to compensate for viscosity fluctuations and backflow barrier leaks .
A team representing the UK’s finest young robotics talent, and supported by factory automation specialist FANUC UK, has been honoured at WorldSkills Lyon 2024, known as the ‘skills Olympics’.
Jason Scott and Charlie Carson, both from Northern Ireland, were awarded the Medallion for Excellence in the category of Robot Systems Integration, in which they competedagainst teams from 18 different countries. The duo attended Northern Regional College and Jason now works at AES Global while Charlie attends the University of Ulster. They began their WorldSkills journey back in 2022, competing against teams from across the UK in a series of robot challenges set by FANUC and ably supported by representatives from the automation company. After being selected by WorldSkills to represent the UK in the international finals in Lyon, the pair were delighted to be recognised by the judging panel for their hard work and talent, with teams from China and Korea jointly named as the overall winners.
Over 1,500 young people from 69 countries competed over four days of tough competition in 62 different skills at WorldSkills Lyon, which was watched by over 250,000 spectators.
FANUC UK is now turning its attention to supporting the next crop of young robotics enthusiasts. The final of the 2024 WorldSkills UK Robot Systems Integration competition will take place at the FANUC UK Open House event in Coventry on 12-14 November 2024, where the country’s most talented teams will battle it out in a series of automation challenges set by FANUC’s in-house robotics experts. Winners will have the chance to represent Team UK at the next WorldSkills competition, which takes place in 2026 in Shanghai, China.
“Encouraging, supporting and championing the next generation of robotics engineers is something we are extremely passionate about,” says FANUC UK Managing Director, Tom Bouchier. “Each year we are blown away by the level of talent and enthusiasm shown by the WorldSkills UK competitors and this year is no exception. Seeing the success that Jason and Charlie have enjoyed in Lyon will only serve to inspire these young people even further, and I can’t wait to see what they achieve in November.”
Ben Blackledge, Chief Executive, WorldSkills UK adds: “High quality skills development is crucial to growing the economy, and Team UK’s medal-winning performance in front of a global audience sends a strong message that the UK is a world-class place to invest, develop talent and create jobs.”
To register for the FANUC UK Open House 2024 (Ansty Park Coventry, 12-14 Nov), go to https://ukopenhouse.fanuc.eu
Charlie Carson (left) and Jason Scott (right), both from Northern Ireland, were awarded the Medallion for Excellence in the category of Robot Systems Integration.
Young people from 69 countries competed over four days of tough competition in 62 different skills at WorldSkills Lyon.
An ounce of prevention is worth a pound of cure, said Benjamin Franklin over three centuries ago. Never has this sentiment been truer in today’s fast-paced production environments. Access to real-time information not only transforms service models and increases machine uptime, it also leads to better and faster business decisions, greater process transparency and higher productivity.
During the recent European Productivity Roadshow, visitors explored how three Sumitomo (SHI) Demag remote connectivity systems – activeConnect, myAssist and myConnect – are being deployed by customers to diagnose, troubleshoot and resolve issues faster. In addition to increasing machine availability and reliability, these remote service systems also inform better operational decisions and contribute to higher productivity. Without compromising security and sensitive data.
Marking this next phase in the evolving remote diagnostics and predictive maintenance journey, Sumitomo (SHI) Demag walked visitors through each connectivity option. Linking to the IntElect 75 ton production cell within the Roadshow truck, processors got the chance to view the support and diagnostic functionalities in a simulated ‘live’ production environment.
The uptick in interest for real-time remote machine monitoring has really started to accelerate, emphasised Technical Manager Nick Stockton during the four-stop tour of the UK and Ireland. Highlighting the user-friendly benefits of the my Connect option, Nick reaffirmed how this solution enables the company’s helpdesk experts to resolve issues faster and save money by connecting to a machine in the field.
Connectivity cost savings
Utilising cellular 4G and 5G networks, a private APN and encrypted VPN, more than 400 of the company’s injection moulding machines in the UK are now equipped with the activeConnect product developed by Sumitomo (SHI) Demag UK. This PIA award-winning solution was intentionally designed to overcome the challenge of negotiating approval to access the company’s IT infrastructure. Something that many manufacturers with advanced IT architectures and firewalls prohibit. “Connection to the service management system is only established when the machine operative enables the system,” assures Nick.
Once connected to the machine, the company’s technical experts can observe, fault find, identify process problems and identify any required parts. Resulting in a first time fix rate of over 90%.
Quick to install, within minimal business interruption, Nick estimates that the annual subscription to connect four of their company machines on activeConnect costs the equivalent of an engineer’s average daily callout rate. “This is a small price to pay for optimising productivity, maintaining operational efficiency, increasing machine availability and saving money,” emphasises Area Sales Manager Ashlee Gough.
Predict and protect
Similar to the SDUK activeConnect product, myConnect offers the same screen to screen connectivity, in addition to a more comprehensive and modular service support platform. It enables customers to integrate and capture data on their entire site production. For maximum security, myConnect connects to the central server via a secure VPN tunnel and places a request in the Sumitomo (SHI) Demag service messaging system.
The fully integrated ‘Site Controller’ within each machine enables various machine parameters to be called up and allows visualisation of production data at any time and from anywhere. Combined with myAssist, end users can define and access easy to read dashboards, consumption data and KPIs.
This level of high data transparency makes it possible to spot deviations, aggregate data captured from all OPC-UA filtered sources and react to changes in production processes at the earliest stage. The ability to merge data from multiple sources facilitates complete digital mapping of all production and environmental factors, including historical data. The addition of Human Virtual Interface (HVI) and an Expertise module to myAssist, also enables users to put data findings into context by adding labels and more detailed annotations.
“By analysing data from a variety of sources, customers can receive better predictive maintenance recommendations. This enables engineering managers to create maintenance plans to prevent unplanned breakdowns, in turn helping to protect assets by extending the lifecycle of machines,” adds Nick Stockton.
Download the company’s Make More For Less productivity whitepaper to discover how remote diagnostics can increase production yields and virtually eliminate machine downtime. https://sumitomo-shi-demag.co.uk/make-more-for-less
At the recent Productivity Roadshow, visitors explored how technologies like activeConnect, myAssist and myConnect can be deployed remotely to diagnose, troubleshoot and resolve issues faster.
What a great story… so pleased to hear from Robert after all these years and to hear of his success .. we’re delighted to be back in touch with someone we’ve helped along the way..
I recently reached out to the PMMDA Trade Association, which sponsored me during my time at Coventry University 20 years ago. This sponsorship was awarded as a prize for winning a design competition while I was Product , Auto and Transport Design Coventry University. Reflecting on this experience, I recognised the importance of understanding the impact of such programs from an employer’s perspective.
Manufacturing is one of the UK’s success stories. With an output valued at £224bn, we are now the eighth largest manufacturing nation in the world. But our position is vulnerable unless we significantly increase our level of automation.
Helping manufacturers to increase their productivity, reduce waste, improve product quality and alleviate labour shortages, the benefits of automation are myriad. And as the only G7 country to sit outside the top 20 in terms of robot density (we are actually 25th in the IFR global robot league table), accelerating our automation uptake is essential if we are to retain our place as a leading manufacturing nation.
It is therefore important that when designing a new product, planning a new production line or upgrading your existing facility, automation is factored in from the very start of the process, not just as an afterthought. Not only does this keep down costs, it also ensures that any automation will be right first time, minimising downtime, boosting productivity and resulting in a solution that is fit for purpose.
Here, Oliver Selby, Head of Sales for FANUC UK, outlines six key design considerations for seamless automation integration…
Embrace the automation process
It may sound obvious, but keep front of mind the fact that your product’s manufacturing process will need to benefit from automation. This can generally only be done by incorporating automation into the design of the product, whether that’s by giving the part a feature that allows it to be picked up by a robot, located or inspected by a vision system, or allowing access for a welding torch or fixturing, for example.
This mindset also translates to the wider production line. We see products designed using multiple materials, joining techniques and production methods which won’t all necessarily work together to produce something that is easily automated, but which designers are reluctant to give up. However, it can be better to take a hit on one material or process to make things easier to automate, thereby reducing overall production costs.
Prioritise parts
Focus on part delivery methods within the complete solution. Often, customers will come to us looking for an automated solution, but with their component parts delivered in no ordered way. As much as 20-30% of the cost of the project can be spent on getting those parts located or fixtured and ready to process before the real automation process can actually begin. It makes more commercial sense to keep parts in order, whether that’s in a nested box, on a conveyor or in a stack.
Also think about part handling and fixturing. Significant costs could end up being channeled into part fixturing – even more so if you are working with a range of parts due to multiple fixtures. A good example of best practice here is to focus on one-way assembly; for example, where parts stack on top of each other to create the complete product or common part features that allow common fixturing.
Consider TCO
Concentrating on the wrong drivers for automation is a major error but one that we sadly see all too frequently. Some customers are more focused on fitting an automation solution into a defined payback period (often under two years) instead of looking at the value it will bring to the business over its lifetime. A total cost of ownership model is a far better measure. Purchase price only accounts for between 15-25% of the total cost of ownership; the remainder is made up of factors such as maintenance, energy usage, repairs, and even end of life. Measuring TCO rather than ROI will ensure you get the right automation solution for your business, resulting in real long-term value.
Remember the process, not just the consumer
It can be tempting when developing a new product to prioritise what’s easiest for the consumer, without realising that this may negatively impact the automation process. A prime example of this is shelf-ready packaging. The current trend within food manufacturing for front-facing packaging with tear-off flaps or loose fitting lids allows retailers quick and easy restocking of shelves. However, this seemingly simple change in packaging design has made it extremely difficult for automation to be exploited for end-of-line palletising, as the loose fitting lid or tear-off flap is not conducive to staying in place. Therefore, before making any packaging changes – no matter how seemingly minor – think carefully about how they may impact your ability to automate, and the effect this will have on production efficiency and labour demand.
Talk to automation suppliers
Engage with automation suppliers as early as possible. At FANUC, we are more than happy to support designers that are beginning their journey towards automation and will readily provide guidance on what the process is going to involve. We’ve done this countless times throughout the years as different sectors have started to embrace automation – from manufacturers of low-cost products to high-value goods; companies in the food industry; and more recently, with EV battery manufacturing for the automotive sector. We have rounded experience across lots of different applications within a wide range of industries that we are happy to share, and which designers can learn from.
Try before you buy
Finally, as in many industries, some automation suppliers are now starting to offer low-cost/low-risk routes into automation for companies taking their first steps into automation. Robots as a Service (RaaS) is a subscription-based option that enables manufacturers to pay a set fee over a specified period of time, and effectively lease a robot to use in their facility. The limitation of this offering is that it will only suit certain simple applications, for example, palletising, or particular welding options. The upside is that the robot can be repurposed for multiple product types – palletising a box of cakes is effectively the same process as palletising a box of dishwasher tables, for instance. Talk to your automation supplier to determine if RaaS could be right for your needs in the short-term – by allowing firms to test the water and experience the benefits before making their own investment, it can represent an affordable route into automation for some first-time users.
Online procurement and marketing hub PlastikCity has today announced the launch of PlastikCity Insurance, a new venture which offers tailored insurance solutions specifically designed for businesses operating within the plastics sector.
PlastikCity Insurance, in partnership with PHL Insurance Brokers Limited, provides comprehensive coverage options, competitive premiums, and dedicated service. With an in-depth understanding of the unique risks faced by plastic manufacturers, the new service ensures businesses receive the right policy from specialist insurers.
Comprehensive Insurance Solutions for Plastics Businesses
PlastikCity Insurance is committed to providing bespoke insurance solutions that cater to the unique needs of the plastics industry. The offerings include but are not limited to:
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Business Interruption Insurance: Ensures businesses can maintain cash flow and operations in the event of unforeseen disruptions.
Cyber Insurance: Protects against cyber threats and data breaches, crucial for modern businesses relying on digital operations.
Expert Guidance and Tailored Policies
PlastikCity Insurance stands out by offering expert guidance and tailored policies. Each policy is crafted after a thorough assessment of the client’s specific requirements, ensuring comprehensive coverage without unnecessary costs. This personalised approach ensures that every business receives the most appropriate protection for its unique circumstances.
Competitive Premiums and Comprehensive Coverage
Working with specialist insurers, PlastikCity Insurance guarantees competitive premiums without compromising on coverage. The collaboration with PHL Insurance Brokers Limited, a well-established insurance broker with a proven track record, adds to the credibility and reliability of the services offered.
Unmatched Industry Knowledge
PlastikCity’s extensive experience in the plastics industry provides an unmatched understanding of the challenges and risks involved. This knowledge translates into more relevant and effective insurance solutions, making PlastikCity Insurance a valuable partner for any business in the sector.
Easy and Efficient Process
The process of obtaining a policy through PlastikCity Insurance is streamlined and efficient. Businesses can easily request a free quote through the dedicated website and receive a detailed assessment promptly. The team of experts is always available to provide support and answer any queries, ensuring a smooth and hassle-free experience. Additionally, for every quotation request sent through the website, PlastikCity Insurance will donate £25 to the Air Ambulance Service charity.
Welcome to our latest member CARVECO, its great to have you on board, especially as we have a connection spanning over 20 years, we all look forward to working with you. Catch up with you soon at one of our events…
ABOUTUS
The Carveco™ software range is the trusted CAD modelling and CNC machining solution to a multitude of industries worldwide.
The easy-to-use, yet immensely powerful, tools included in Carveco software give sign-makers, woodworkers, engravers, jewellers (and countless other creatives) the freedom to design and manufacture high-quality 2D or 3D products from their artwork, faster than they’d ever thought possible.
