Category: Engineering

Manufacturing has suffered heavily due to COVID-19. Warehouses had their operations shut down for months, and government guidelines demanding social distancing and other measures means that some companies will be working at a reduced capacity and are playing catch up to make a dent in their losses.

Fortunately, the UK government has offered to boost the country’s manufacturing capacity with an investment of £300 million in joint government and industry funding. It will be used to fuel innovation in areas like robotics, AI and augmented reality.

The investment will provide a crucial financial boost to the aerospace, automotive, pharmaceuticals and food and beverage sectors across the UK as the country builds up following the impact of the Coronavirus pandemic.

The investment comes through the Manufacturing Made Smarter competition, which was a project aimed to help UK manufacturing supply chains develop technologies that make operations more efficient, productive, flexible and resilient. Firms of all sizes could apply for up to 70% of the funds they need for their research projects. The government will invest £147 million, with the rest of the £300 million backed by funding from the industry, to support businesses using new technology in manufacturing.

£50 million of the funding is being given to 14 manufacturing projects that involve a mix of SMEs, larger businesses and universities, whose applications for the Manufacturing Made Smarter competition were successful.

One such successful project is Digital Designer Robot, which offers machine-to-person digital assistance. The idea is that when a company needs a bespoke product, they can use a digital robot to help with the design, which can then be quickly uploaded to the supplier’s website, allowing for a quick turnaround of sampling, and a prototype is manufactured.

Another successful project is the Smart Connected Shop Floor. Using real-time data integration, this digital technology includes augmented reality headsets for engineers so businesses can guide them through repairs, and the use of smart devices to exchange information between computer systems.

The Digital Sandwich is a project that involves digitalising the food supply chain, helping a sandwich supplier serve the NHS during the Coronavirus pandemic. They are creating software where food and drinks companies can connect and share data. This information exchange will be used to boost productivity, improve cash flow and reduce waste within the supply chain.

Business Secretary Alok Sharma confirmed the funding for these projects at London Tech Week; he said that: “Increasing productivity is vital for any business, and having the right new technologies in place can help manufacturers make better products to compete and thrive.”

How Can Technologies Help Manufacturing?

COVID-19 has caused many difficult challenges across all industries, especially manufacturing. Manufacturers must invest in the right kind of technologies that provide unique, digital solutions to supply problems so they can continue to survive during these uncertain times.

The pandemic has caused disruptions to normal operations thanks to lockdowns and travel restrictions. Workers need safe access to their workplace where they can keep a safe distance from others while coping with a reduced workforce. Fortunately, technologies can be used to optimise manufacturing processes, helping businesses to not only survive but thrive during these uncertain times.

• Planning

Planning is a crucial part of manufacturing and supply chain operations. This is often handled by the people in charge, possibly by separate teams. But the pandemic has forced businesses to improve their company visibility so they can make cost-savvy decisions, and the impact of good planning is more evident.

This is where autonomous planning can come into play. Artificial intelligence and machine learning algorithms can use both internal and external datasets from suppliers, customers and broader economic indicators to incorporate variables and help companies respond to changing dynamics. This technology can optimise the planning processes across the entire chain, providing end-to-end visibility and allowing decisions to be made based on strategic modelling that produces cost-effective results.

• Manufacturing goods

The manufacturing of goods has been put under strain thanks to COVID-19. Companies now need to cope with social distancing measures, a staggered workforce and restricted movement of migrant labour between countries. Fortunately, digital technologies can help with employee safety, operational efficiency and productivity.

Digital technology helps with remote working and collaboration, reducing the footfall in physical warehouse locations. Location tracking mobile apps and wearable technologies can also help workers maintain social distancing as they start to go back to work.

Many processes can be automated through the use of robotics, helping workers cope with a reduction in their workforce and reducing contact between employees. These robotic workers can supplement labour capacity, taking over some of the simpler, or dangerous, tasks and freeing up human workers to do the more intricate work that AI is not capable of performing.

Aside from the actual manufacturing processes, digital technologies can also help with quality assurance. Machine-vision algorithms can perform quality inspections using predictive algorithms, relieving human employees of this role while increasing the precision of quality checks.

• Delivery

Delivering manufactured goods is a complex process that often involves third parties. The pandemic has reduced transportation and added new challenges such as contactless delivery and transport restrictions. That’s why digital solutions can be used to help increase visibility and improve deliveries across the sector.

From loading at the collection point to unloading at the delivery point, digital fleet management, route optimisation and carrier analytics can optimise operation, management and resource allocation. Telematics and on-board sensors, combined with machine learning, can help improve driver behaviour, increase fuel efficiency, reduce maintenance costs and minimise asset downtime.

Warehouses can be fitted with automated storage and retrieval systems, smart shelves, and picking robots and drones to help optimise delivery processes. Augmented-reality tools can also be used to make picking multiple orders more manageable and more effective, and the use of exoskeletons can help reduce the possibility of injury to workers lifting heavy materials.

COVID-19 has created many challenges for manufacturing, but for those that invest the right kind of technologies, they can improve their processes, streamline operations and boost their cash flow. At European Springs, we are expert spring manufacturers; if you’d like to learn more about our services, contact us today.

The manufacturing industry of today is unrecognisable compared to 30 years ago, so it makes sense that the future of the industry won’t look anything like it does now. Manufacturing in the UK in 2050 is set to be a much eco-friendlier production. Recycling will come into play more, and entire factories could be powered by nothing but renewable energy.

Embracing this new, greener future is an exciting but also vital prospect. Climate change is a real issue affecting all industries, and a shift towards more sustainable ways of operating is necessary and unavoidable. The UK needs to make this transition by decarbonising its processes along the supply chain and reducing the carbon required in manufacturing.

Why is Green Manufacturing Important?

Climate change is causing sea levels to rise, water shortages, heatwaves, flooding, and more disasters the world over. The issue is only set to get worse, so the challenge is to meet these problems head-on and come up with innovative solutions.

The UK manufacturing industry is the ninth largest in the world and accounts for 42% of UK exports. When we take into account all the impacts of the UK manufacturing industry, the sector makes up around 15% of the UK’s economy. Manufacturing will have to cope with much of the structural changes needed to tackle the climate change problem.

Everything from energy, transportation, industrial processes, agriculture, and more will need to shift towards ridding themselves of the old, carbon-intensive processes. Switching to low carbon technologies and more efficient use of resources is one of the manufacturing industry’s greatest challenges. Clean energy is expected to be one of the largest markets of the 21st century, set to be worth more than £100 billion by 2030. So while the switch might be costly in the beginning, the future opportunities far outweigh the risk.

New technologies and innovations can help to completely reconstruct how industries like manufacturing operate. The decarbonisation of manufacturing is a big opportunity for the UK economy, raising productivity and creating sustainable jobs. By getting more out of existing resources, manufacturing can drive sustained productivity growth.

How Manufacturing is Changing

Manufacturing is already seeing a big shift towards more sustainable ways of working. While COVID-19 managed to bring the industry to a standstill and significantly impact the UK economy, it may actually have provided a boost to the shift towards more sustainable manufacturing practices.

Research shows that more sustainable practices often lead to a bigger profit, and businesses that invest in sustainability will reap the benefits. Before COVID-19, The Manufacturers’ Organisation UK found that 30% of manufactures were investing in energy-efficient measures, with 40% reporting an increase in profits as a result. In fact, 90% of manufacturers are aware of the 2050 net-zero target instated by the government, and nearly half of them were already committed to finding ways to help meet this.

Manufacturers were already starting to switch to greener practices, but it looked like COVID-19 has accelerated this, with many businesses wanting the government to offer energy-efficient measures to aid a green recovery from the pandemic. As manufacturers return to work, and learn some key lessons as a result of the virus, more opportunities have opened up to improve sustainability, transform the way the economy operates and work towards a green recovery.

Technological innovations are the driving force behind green manufacturing practices. In the supply chain, processes and products can be decarbonised, reducing the carbon needed to produce the products, making them more efficient; this involves design improvements and efficiency-enhancing techniques such as using smart technologies. Use of data analytics and robotics can help production lines revolutionise the manufacturing process.

Take, for example, the car manufacturing giant Ford. They have already adopted VR, allowing them to bypass having to use up resources building physical model prototypes. Instead, a VR model is made, and this is used to workshop ideas and changes, lessening their environmental impact as they do not waste valuable resources.

Companies that invest early will have greater success in diversifying future products and markets. The UK manufacturing industry is well placed to make the transition to eliminating emissions. Through the Climate Change Act of 2008, the UK became the first country to set a legally binding emissions-reduction target, setting a precedent for industry decisions.

So far more than half of the electricity in the UK comes from low-carbon sources, 39% of which comes from renewables. The offshore wind capacity is higher than any country, 40% of the total worldwide, and the electric car industry in the UK accounts for 6% of the global market, ranking it sixth in the world in 2018.

The UK has a strong advantage in creating these innovative technologies to help drive sustainability. The reasons for this include:

• A competitive product market
• A flexible labour market
• World-class universities providing excellent graduates
• Globally competitive firms in manufacturing

With continued investment and support, the UK government could help the manufacturing industry become a world leader in green manufacturing. The challenge is complex, involving a delicate balance between remaining competitive and maximising potential. With both Brexit and COVID-19 taking over the government’s focus, it could be a long way off, but there is reason to be optimistic about the UK’s ability to tackle this green transition head-on.

At European Springs, we take a vested interest in manufacturing news. We are expert spring manufacturers based in Kent and Cornwall. Contact us today to find out more about our services.

As one of the leading spring manufacturers in the UK, and with over 70 years’ experience in the industry, we get asked plenty of questions when it comes to springs! Read on to see the answers to some of the most frequently asked questions that we are commonly asked.

How Do Springs Work?

Springs work by using stored energy when pushed or pulled out of their natural shape.

Springs can store energy, and the tighter a spring is – the more force it will take to deform it. In physics terms, a spring can store potential energy due to its elasticity. The elastic limit is the maximum amount of force that a spring can take before it is permanently deformed.

There are engineering steps that can be taken to increase or decrease a spring’s elastic limit, such as adding more coils to the spring or making the coils tighter.

How Do Compression Springs Work?

Compression springs resist compressive forces as they are applied. When a heavy object or force is applied to the spring, it condenses, and pushes back with equal force until it is eventually released.

They are also sometimes referred to as open-coil helical springs.

Do Springs Wear Out from Being Compressed?

If a spring’s elastic limit is exceeded by using too much force on the spring, then a spring will become deformed and worn out.

Alternatively, your spring might be suffering from spring creep. This refers to when the material slowly deforms over time, but this shouldn’t happen if the spring’s elastic limit is not exceeded. Getting your springs custom made for your application can also help to prevent spring creep.

Do Springs Lose Tension Over Time?

Much like springs that are compressed too far, a spring may become deformed if pressure in excess of the spring’s elastic limit is used. Spring creep is a term that refers to the deformation of a spring over time, and can be avoided by getting your springs custom made to suit your application’s requirements. You can read more about Spring Durability and Fatigue here.

What Is a Torsion Spring?

A torsion spring exerts force proportional to the force being applied, but in the opposite direction, and can be designed to work clockwise or counter-clockwise. They can be designed in a variety of sizes.

What Are Springs Made Of?

Springs can be made out of all kinds of materials, but the material chosen will dictate the boundaries of the elastic limit. Here are some examples of popular spring materials:

• Hardened Steel
• Bronze
• Titanium
• Plastic

Which Type Of Spring Is Right For Me?

Choosing the right spring for you will completely depend on exactly what your requirements are. To ensure you’re getting the right type of spring, we would recommend getting in touch with our experts today via our simple online enquiry form, or by calling the closest European Springs & Pressings facility to you.

What Are Pen Springs Made Of?

A pen spring is usually made from stainless steel. The type of spring used is a compression spring which enables the nib of the pen to retract when it is not in use.

How Do Gas Springs Work?

A gas spring uses compressed gas sealed by a sliding piston to pneumatically store potential energy. Like a metallic spring, it withstands external force applied parallel to the direction of the piston shaft, and pushes back with equal force.

What Is Press Forming?

Press forming is a manufacturing technique used to create parts. A pressing force is applied to a material that pushes the material into a die mould. This force deforms the material so that it takes the shape of the die and maintains that shape forever.

What Is Metal Stamping?

This is a manufacturing process used to convert flat metal sheets into specific shapes using a die and pressing force. It involves placing a blank sheet of metal into a stamping press, and is used to punch, blank, bend, coin, emboss, or flange the metal.

Advantages of Metal Stamping

Metal stamping is a cost-efficient method for producing high volumes of the same design. It also produces great quality and accuracy, so it is favoured by many industries today.

How Are Springs Manufactured?

To make a spring, a coil of metal is placed onto a hot former, which curves the wire into the correct shape. After that, the top and bottom of the spring is ground flat so that it sits evenly on flat surfaces.

What Is The Pitch Of A Spring?

The pitch of a spring will differ depending on which type of spring you choose, and the size of that spring. The pitch is determined by measuring between the centres of two coils.

Press Forming Advantages

It is possible to create thin parts in complex shapes cost-effectively using press forming. It is also easy to request parts in different colours and finishes, though there are some exceptions to this rule.

How Long Will My Spring Last For?

The amount of time that your spring will last will depend on several variables such as the type of spring that you require, the intended use of the spring and how often the equipment the spring is installed within will be used.

Driven by the need to access insights in real-time, Industry 4.0 is the name that has been given to the current phase of the industrial revolution. It’s heavily focused on integrating smart technology, automation and machine learning, with current manufacturing practices.

We will be looking at whether the manufacturing industry is ready for these big changes. Are we ready to embrace Industry 4.0, and more importantly, what role will it play in building a new strategy after Covid-19?

Is the Manufacturing Industry Ready for I4.0?

Industry 4.0, sometimes abbreviated to I4.0, will bring significant change to the way our nation’s manufacturing companies are run. Increased automation will mean that fewer production line jobs will be required, profits will be made from increased output and efficiency, and that this profit should initially be invested on training bottom line workers to successfully oversee and maintain mechanical operations.

The question of whether Industry 4.0 is happening is a moot point: the revolution is already in progress. The real question, then, is whether our nation’s businesses are ready to take advantage of this new technology, and what will become of those companies that fail to invest in automation soon enough.

Overall, statistics report that our nation’s manufacturers at large are ready and willing to embrace big changes. In fact, the Annual Manufacturing Report from 2019 found that 81% of manufacturing companies wanted to invest in new technology to boost productivity. Many will note, however, that there is a marked difference between wanting to invest and being ready to.

Are You Ready for Industry 4.0?

If you are one of the companies that are keen to invest in Industry 4.0, then there are a few things that you can do now to make sure that you are ready to implement this new technology as soon as you are able.

Here are some questions that you should be asking yourself:

Can I Cover the Potential Costs of I4.0?

Installing the technology will have its own costs, so you will need to prepare a substantial amount of savings for your business before you can consider cashing in on the benefits of I4.0 technology. Finding this money starts with speaking to the creators of I4.0 technology and getting rough estimates on potential costs for your business. From there, it is a matter of making good savings until the equipment you need becomes available.

How Will My Staff Need to Change?

Understandably, your bottom line might feel a little intimidated by the eventuality of Industry 4.0 technology, and as a good employer, this is an anxiety that you should try to address. Inevitably, the shape of your current board of staff is sure to change as efficiency improves and more technological maintenance is required. If you’re sure that you are going to be implementing I4.0 technology in your business, then you should be considering costing up future training for your employees now.

Can and Should I Wait to Implement this Technology?

There are two different schools of thought regarding whether or not you should dive into new technology the moment it hits the market. On the one hand, this technology could help you to move beyond your current competitors as you improve your efficiency and gain more time to focus on staff retention, customer loyalty and marketing.

On the other, if you are a little sceptical about how advanced logistics, immediate data reports and automatic inventory calculations will help your business – waiting a while to learn the truth of how this technology has benefitted other businesses may permit you to cost up the advantages of investing in this technology more effectively. Until the technology becomes more widespread, it is hard to judge the precise effects that this investment will have for you.

What Are the Green Benefits?

We are tension spring manufacturers who are interested in green responsibility, and we believe that I4.0 has the potential to reduce waste in manufacturing. With improved logistics, manufacturing will be able to better understand where waste is occurring and discover ways to reduce this. Doing so should have economic benefits for the company, too, so it’s happy all round.

If you are in need of spring manufacturers for your next project, we’re experts in the industry. We combine smart technology with decades of experience. For custom springs or opinions on the latest industry trends, you can rely on us.

The Coronavirus pandemic has brought about a number of changes in the way that each and every one of us live our lives on a day to day basis. Not only that, it’s also brought about significant changes in the way that all sectors operate in the workplace, and that’s no different for the manufacturing industry.

Robotics have played a vital role in manufacturing for a number of years now, but in recent months there’s been a real reliance on autonomous machines due to a lack of human staff being able to work within factories up and down the UK.

As one of the UK’s leading spring manufacturers, we understand just how important IOT and robotics are to the future of the manufacturing industry, so our experts give some of our insight into the main reasons the sector needs to invest in robotics in the coming years.

IOT & Smart Factories’ Vital Role During Pandemic

Before the Coronavirus pandemic swept across the globe, IOT and Smart Factories were already well-established within many manufacturing businesses around the world, and there is good reason for this. From being able to autonomously work all hours through the use of robotics, to equipment being able to accurately assess when it requires maintenance work, or if product quality was slipping, these innovations have already started to shape the industry for the better. COVID-19 has simply accelerated this process and reaffirmed the need for robotics in the industry.

With employers now needing to take into account a whole host of health and safety issues, including adhering to social distancing measures in the workplace, along side maintaining staff well-being, robotics in manufacturing really does come into its own.

We have already seen many companies continue to thrive during and after the height of the Coronavirus pandemic, with equipment being able to autonomously work alongside a skeleton staff of human employees to ensure products created are of the highest standard. This has played a vital role in keeping many businesses within the manufacturing sector afloat, whilst also ensuring that social distancing measures are easily adhered to within the workplace, keeping all employees safe.

Robotics Take Giant Leap During Pandemic

There’s no denying that robotics have been a key part of the manufacturing industry for some time, but in recent months there has been a huge leap in the productivity and innovation seen within the robotics industry. The COVID-19 pandemic has given robotics experts from around the world a real impetus, as they race to develop and deploy innovative technological solutions that are capable of addressing the numerous challenges faced by a huge range of industries due to the current crisis.

One of the major developments to come about this year is seeing robots capable of performing disinfection tasks in public and commercial spaces. Utilising robots to disinfect workplaces could well become the norm, especially in the manufacturing industry, as autonomous equipment is already playing a vital role in the supply chain. By reducing the need for human interaction with potentially infected areas, businesses can rest assured they are doing everything within their power to reduce the likelihood of any COVID related outbreaks within their workplace.

Whilst it’s fair to say that robotics are constantly evolving, there is still a need for robots that are capable of fulfilling more than one task. This has been an area of focus for researchers for a number of years now, as the need to shift to multi-task robotics has grown in demand from companies around the world. The advancements we have seen during the Coronavirus pandemic has certainly given many scientists and robotics developers the confidence that creating autonomous innovations can be done in a short space of time, it’s now up to developers to take the next step in providing multi-purpose robotics.

For the manufacturing industry it would be ideal to see a robotic solution that is capable of not only creating products and highlighting when it is due to either breakdown or requires maintenance, but also actively fix any internal issues by itself. This would take a lot of pressure off engineers within manufacturing businesses, as the autonomous machines could effectively work completely alone to some degree.

Want to find out more about the latest developments in the manufacturing industry? Be sure to regularly check in on our news page as our experts are constantly giving their take on the latest and greatest innovations within the sector, as well as sharing the very latest company news coming out of European Springs & Pressings!