I, Robot – you, engineer
Author : Kieron Salter, managing director, KWSP
17 October 2017
Too many UK manufacturers are put off implementing 4IR strategies due to perceived high cost and risk. However, there are plenty of opportunities for engineers to digitise parts of existing processes to get to grips with Industry 4.0, says Kieron Salter, managing director of high performance engineering consultancy, KWSP.
Recent figures from the Engineering Employers’ Federation (EEF)* confirm that only 11 percent of manufacturers think that UK industry is geared up to take advantage of 4IR. Furthermore, statistics from accountants PwC show that UK companies are planning to invest on average seven times less than their German counterparts in 4IR over the next five years.
This is a huge shame, according to Salter, as the UK’s industrial maturity gives it a natural advantage in the area of 4IR and the opportunities emerging in the era of mass customisation. The problem for many engineers lies in the jump from traditional manufacturing into the world of digital. Big data, additive manufacturing sensors and PC controls can all seem a bit daunting to experienced production engineers; but there is a low risk approach to 4IR that many more manufacturers should be considering.
Kieron Salter said: “Understandably, many firms baulk at the idea of investing in digital manufacturing technology, given the fact that they’ve got many thousands of pounds tied up in existing CNC machining, tooling and other equipment. However, we’ve found that identifying easy wins or low hanging fruit, can be a good way of demonstrating the tangible benefits of 4IR.”
4IR is often represented in the form of total digital manufacturing systems, which use huge amounts of real-time data to produce production quantities of ‘one-off’ items without the cost of new tooling, but there is another interpretation of 4IR that is perhaps more appealing to many manufacturers.
This approach uses digital control systems to improve the performance of a specific stage within a larger manufacturing process. Typically, this might involve the more accurate deposition of industrial adhesives to a complex component, which is made of several different parts. In this example, digitisation has improved accuracy, reduced failure rates and significantly cut down on material use. Employing digital controls here has also improved productivity.
Kieron Salter, managing director, KWSP
Another area where digital control could be quickly utilised is screen printing, a process typically used to apply adhesives to laminated bonded parts. This process is seen in the manufacture of automotive windscreens and kitchen worktops. Here, adhesives are usually applied using screen printing. Replacing this with a digital process allows you to print only where the adhesive is needed. It therefore cuts down on material use and provides endless opportunities for personalised products and flexible manufacturing processes.
Salter concludes: “Adopting 4IR need not involve huge amounts of cost, risk and major process change. By bringing digital and connected controls into a manufacturing process, businesses can cut costs, reduce waste and achieve better quality control.
“4IR offers huge opportunities for UK manufacturers. Remember, it’s not all about totally digitised processes – you can adopt software to use 4IR technology where you need it.”
* November 2016 - The 4th Industrial Revolution – a primer for manufacturers
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