Category: Engineering

There is no doubting the fact that manufacturing will become increasingly reliant on AI technology in the coming years. To some extent, there is already a significant amount of reliance on AI within the industry, especially in the US and China. But just how does the UK stack up in terms of AI investment in the last year?

In this blog, we will answer that question, whilst also giving you some insight into exactly what AI is and some of the major applications it is used in within a manufacturing environment.

What Is AI?

Artificial Intelligence (AI) refers to any task that is performed by a machine or a program, that if a human had carried out that exact same activity, we would suggest that the human had to apply intelligence to accomplish the task. This is a pretty broad definition, so another way of looking at AI is that it will usually display some of the following human behaviours:

• Perception
• Learning
• Planning
• Problem-solving
• Knowledge representation
• Motion
• Reasoning
• Creativity
• Social intelligence

What Can AI Be Used For?

AI is used extensively throughout a whole host of industries, but it’s also used in many products and applications that the average person will use in day-to-day life. A great example of AI technology that is used by a huge percentage of the population every day would be virtual assistants such as the Amazon Alexa or Apple’s Siri.

In manufacturing terms, AI is used extensively throughout the industry, with the technology used to:

• Conduct Quality Checks – Quality checks of all products is an essential part of the manufacturing process. Having AI technologies conduct product checks is a fantastic way to lighten the workload of employees, whilst also guaranteeing the precise accuracy of each and every product manufactured.
• Carry Out Predictive Maintenance – Equipment and machines breaking down can cause real issues for manufacturers, as they will have to put measures in place to operate at normal capacity during the equipment’s downtime. It’s therefore essential to prevent downtime where possible, and with AI technologies, there is a real opportunity to do so. Predictive maintenance has quickly become one of AI’s most important roles in the manufacturing process, as the technology can give insights to engineers when a machine or equipment is likely to breakdown or require maintenance. This can help reduce machine downtime from days or weeks to just hours.
• Make Use of Data – Whilst this is a pretty broad statement, there’s no doubt that AI can help gather vast amounts of data and process it in a way which provides valuable insights into how things can be improved within a manufacturing firm. Data gathered could help supply chain and risk management, whilst also providing an overview of predictions on sales volume and product quality maintenance.
• Digital Twins – AI technology in digital twins gives engineers a clear oversight of the general wear and tear of a machine and how it interacts with other devices. There has been a real surge in the number of digital twins used within the manufacturing industry, as it has helped companies more accurately predict when a machine is likely to break down or when they require some maintenance.

Where Is The UK In The AI Investment League at Present?

There has been a real surge in public and private investment in AI technologies from companies around the world, with the likes of USA and China soaring ahead in recent years.

The top 5, in terms of private investment in AI technology in 2019, is as follows:

• USA – $65 million
• China – $14 million
• UK – $5 million
• Israel – $3 million
• Canada – $2 million

Whilst the latest figures are encouraging from the UK’s point of view, it’s essential for the growth of the UK’s manufacturing industry to continue investing in the latest AI technologies, so they do not fall behind other countries.

Other countries from around the world look set to challenge the UK in terms of private investment in AI in the coming years. The likes of Israel, Ireland, Finland and Singapore, all of which are AI-driven economies of the future, all of which are putting significant funds towards advancements in the technology.

Experts believe that the UK’s footing as one of the world’s largest investors in AI technologies could be genuinely under threat, and without more intensive investment in the coming years, development could be stifled.

Here at European Springs & Pressings, we are always on the lookout for the latest and greatest technologies that are capable of solidifying our position as one of the UK’s leading spring manufacturers. We firmly believe that AI will be critical to the growth of the UK’s performance on the world stage, so it’s essential that our government support manufacturers in implementing AI technologies into businesses as soon as possible.

With the UK officially leaving the European Union on 31^st January 2020, many manufacturing businesses are looking for ways to ensure their business isn’t negatively affected. Whilst it’s fair to say that Brexit will undoubtedly have some teething issues, especially on the manufacturing sector, there are some things that your business can do to minimise its impact.

In this article, we aim to give you a few tips on how your business can overcome the Brexit effect whilst also highlighting what areas have already been affected by the decision to leave the European Union.

What’s Currently Being Affected?

Before delving right into some of the measures that your company can put in place to lessen the affects of Brexit, it’s worth considering some of the biggest affects Brexit has had on the industry.

Workers – As expected, the number of EU nationals working in the UK has steadily declined over the last 3 years. With a large number of employees of UK-based businesses already making the shift to other EU countries – among these workers are a significant number of highly skilled workers.

Weak Currency – In recent years Pound Sterling has taken a significant dip in value against many other currencies. This has caused significant issues for many manufacturers with imports costing more, and it’s fair to say that Sterling doesn’t look set to soar back to early 2000 levels of strength any time soon.

Trade Barriers – Following the EU referendum, input price inflation increased significantly due to a depreciation in the trade weighted value of the pound. With trade deals with other nations around the world currently up in the air, it’s difficult to speculate on just how much of an affect this will have on manufacturers in the UK as of yet.

How Can Businesses Avoid Being Adversely Affected?

Investment in Smart Factory Technologies

Whilst it may sound counter-intuitive to start investing more money into your business in the current manufacturing sector landscape, the importance of Industry 4.0 and Smart Factory technologies cannot be understated. With the ability to save time and money in the long run, by reducing the need for human intervention with the supply line, Smart Factory technology is the future of the manufacturing industry.

In January 2018, the Government released a strategy for a post-Brexit modern industrial strategy that would be put into place over the coming years. This strategy promised billions of pounds of investment in manufacturing technology and Industry 4.0 in a bid to boost the sector to continue competing on a global scale. The manufacturing industry could certainly benefit from significant investment, and the introduction of more Smart Factory technologies could propel UK manufacturers into contention with global manufacturing heavy weights such as China and the United States.

Whilst there has been no official word on when the funding will be available and how it will be distributed, it’s worth keeping a close eye out for news on this in the coming months. Smart Factory technology genuinely has the capability to change the landscape of the UK.

Find A Way To Keep Goods Moving

With the UK officially leaving the European Union, it’s time to start thinking about how you can ensure that your business can continue to import and export the goods you require with little to no interruptions. The major worry for many manufacturers is obviously the costs that may be added to import and export tariffs, but there are also concerns regarding the lead times for importing essential components.

We would recommend that you begin by enhancing the relationships you already have with your current suppliers and the businesses you are currently exporting to. This is an essential step to take as you can work with the companies you are importing from and exporting too to find a suitable work around following the UK leaving the European Union.

One tactic many manufacturers are currently exploring is considering trade opportunities with countries outside of the EU, such as China and the US. Whilst it’s still early days, trade deals will be being explored by the UK Government, so it’s worth taking a look at all of the international trade options you have available to you.

We would also suggest that you are completely clued up on the very latest on trade deals that our Government is trying to strike with other countries, this will inevitably mean that your business is in a position to make arrangements ahead of time.

Invest In Your Staff and Hire The Right People

Our final and probably most important recommendation is that you continually invest in your existing staff and hire the right people to fill any gaps within your business. As with any business, the employees you have in place will either make or break your long-term success, so it’s well worth investing in the people you believe are capable of driving your business forward.

With Industry 4.0 set to play a vital role in the future of manufacturing, it’s imperative that you have a team that is capable of integrating new technologies into your existing work processes. Whether you look to upskill internally, or hire from outside of your business, the importance of having a multi-skilled team cannot be understated in the UK post Brexit.

It’s also worth noting that you shouldn’t forget about bringing in apprentices and graduates into your business. Brexit offers the perfect opportunity to upskill your workers internally, so looking to hire some enthusiastic young employees who are eager to learn can only be a good thing!

Here at European Springs, we take great pride in ensuring that we are always forward planning for the next big technological advancement or political development that could affect our development as a spring manufacturer. It pays to guarantee that your business always has it’s finger on the pulse of the very latest developments within the sector, so be sure to check in regularly on our blog, as we will regularly post updates on the key topics within the manufacturing industry.

In recent years, it’s fair to say that most industries across the UK have experienced some form of a downturn due to the political and economic climate faced by businesses. However, despite the worrying signs for most industries, the manufacturing sector has remained as strong as ever and continues to rival some of the biggest manufacturing nations from around the world according to recent research.

Data gathered by Make UK and Santander has highlighted just how strong the British manufacturing industry has remained, despite external factors such as Brexit and a struggling economy.

We take a closer look at the report and delve deeper into some of the reasons that the UK manufacturing industry has continued to remain so strong throughout 2019.

The UK Ranked 9^th Largest Manufacturing Nation in The World

The UK came in at 9^th in the global manufacturing table for a second consecutive year, which highlights just how stable the sector as a whole actually is. It’s worth remembering that the UK collectively has a relatively small population, one that isn’t even in the top 20 worldwide, which really heightens just how remarkable this achievement is.

The manufacturing industry makes up over 44% of the UK’s global exports, which is worth over £273 billion to the UK economy. It is worth noting that the industry continuing with the trend of exceeding expectations must carry on, even when the UK does leave the European Union, if we are expected to maintain pace with other countries in the coming years.

The sector employs 2.7 million employees in the UK and accounts for around £192 billion of output each year – an astounding feat for an industry that is seen by both the government and wider public as an industry that is in need of modernisation and is in decline. Despite the perception from around the country, UK manufacturers now actually account for 15% of total business investment and an impressive 66% of the country’s research and development spending.

This further highlights just how seriously the manufacturing industry is taking future developments for the sector, with Industry 4.0 in full swing and smart manufacturing technologies being utilised in more businesses across the UK each year.

The report shows that when compared to other countries, the UK ranks well in a whole host of categories, including:

• 10^th for exports of goods
• 7^th for trade
• 2^nd for service trade
• 9^th for GP
• 27^th for GDP per capita

It’s fair to say that the UK manufacturing industry is growing at an unprecedented rate, with a record number of jobs now available in the sector, investment is at an all-time high, and the sector is providing the overall economy with a real boost.

Made In Britain Thriving

Of the global exports, ‘Made in Britain’ products are a success story that has quickly become a global phenomenon – with £118 billion worth of products from this line sold each year to the US alone. There has also been a surge in the Asian markets becoming increasingly important, with China purchasing £23 billion worth of products annually.

The Made in Britain brand needs continued refinement and investment as we look to continually grow the total number of exports of products from this line each year. Beyond the manufacturing industry, Made in Britain, goods across industries are creating a real buzz worldwide. With products from the transport, automotive, chemical and pharmaceuticals, food and drink, machinery, metals, plastics and electronics all performing well on a global stage, the future does look bright for the UK, especially if a trade deal can be agreed with the European Union when the UK does leave the EU.

Here’s a list of the UK’s top 10 export and import destinations for manufactured goods in 2018:

1. United States – £118.2 billion
2. Germany – £55.4 billion
3. Netherlands – £44 billion
4. France – £42.1 billion
5. Ireland – £38.3 billion
6. China – £23.1 billion
7. Italy – £19.7 billion
8. Switzerland – £19.6 billion
9. Belgium – £19.4 billion
10. Spain – £17.6 billion

Here at European Springs, we continue to defy expectations and thrive as one of the UK’s leading spring manufacturers. By continually investing in the very latest technology and equipment, we have managed to keep on growing our business and product offering to our clients.

With AI, robotics and automation commonly viewed as at the cutting-edge of inspirational industry, it may come as a surprise that a significant number of enterprises don’t find that smart working is giving them the outcomes they want. Adidas’ recent decision to close its two “speed factories”, for example, is a powerful example of smart tech that just doesn’t seem to be giving the desired outcomes.

But why is it that so many manufacturers are unable or unwilling to move towards a smart factory model? Here we take a look at some of the main barriers to creating a factory where AI and automated working predominates, as well as some of the major benefits which a smart factory can bring.

Up-Front Costs

There’s no doubt about it, replacing traditional plant and processes with AI and robotic applications requires a significant financial injection. Whilst ultimately this may result in cost savings it can be years before the investment is recouped.

For many manufacturers, the promise of increased revenue following automation is theoretical rather than believable! Particularly in sectors where few companies have gone down the smart factory route, there may not be the concrete evidence to convince decision-makers that moving towards increased automation is going to deliver the required benefits.

Disruption To Current Workflow

Inevitably, the scale of change required to move a factory from a traditional model to Smart operation will require significant disruption. Not only is there likely to be a considerable period of reduced productivity whilst fresh machinery is put in place, but there is also considerable potential for further delays whilst workers learn how to interpret the data generated to ensure optimal results.

There are also inevitably going to be teething problems, particularly when attempts are made to mesh new technology with existing plant in order to create a seamless operation. Although ultimately the benefits may outweigh the drawbacks, in an uncertain economic climate the risk of failing to “hit the ground running” after conversion to a cleverer way of working can often be seen as too great.

Using Data For Maximum Results

The theory behind smart working is that the plant generates data, which skilled operators can then use to inform appropriate decision making. From planning maintenance schedules that deliver optimal results, through to making adjustments to product specifications in order to deliver smaller product runs or a greater diversity of products, the data produced can be used in numerous ways.

Unfortunately, without a workforce that understands how best to utilise the generated data, it’s unlikely that optimal results will be achieved. Similarly, if AI has been introduced piecemeal, there are many challenges to overcome in terms of data integration, storage, security and usage.

More Isn’t Necessarily Better

Although one of the key advantages of smart factories is commonly considered to be the potential for enhanced production, a changing marketplace means that this may no longer be a key priority for manufacturing businesses. Customers are increasingly demanding custom products that match their exact specifications.

For companies engaged in custom spring design or similar, the focus is frequently on creating one-off product batches. In such circumstances, being able to produce “more, faster” (which can be a key advantage of a smart factory), is of less importance.

Skills And Training

Inevitably, fresh technology requires workers who are up-to-speed with how it operates. Smart factories only reach their potential when there are suitable workers available to manage the various operations effectively. The nature of the technology is such that workers need to be comfortable with cross-silo working (for example, having expertise in both maintenance and production), as well as have the ability to interpret and manage large volumes of data.

The acquisition of the relevant skills can require time and investment. In addition, there is a need for a fresh attitude to the working environment, which can take considerable time to embed within an organisation.

Legacy Technology

If it’s not broke, don’t fix it, is an industry maxim! Many companies have invested heavily in a traditional plant, from which their workforce is able to extract impressive performance. For factories which are currently enjoying a good return on their investment and are meeting customer needs, there is little incentive to adopt fresh technology.

In addition, blending new tech with more established plant can create unexpected challenges. It’s often easier (and much cheaper) to fit out a fresh factory with new tech then it is to try and update or modernise and existing enterprise.

Negative Attitudes Towards Automation

There is a cultural resistance to the perceived “march of the machines” which can be difficult to challenge. Although current figures don’t lend weight to the assertion that “robots take jobs”, this is a viewpoint that’s firmly entrenched in many sectors.

Challenging this takes time and education, but may prove difficult, particularly when senior managers, CEOs and shareholders aren’t sold on the idea of a smart factory approach.

Smart Manufacturing Can Have Enormous Benefits

Robotic working and the use of AI reduces the potential for human error to an absolute minimum. Here are just a few of the other advantages that smart factory technology that your business should benefit from:

• Better Customer Care

Smart factory technology allows a much higher degree of responsiveness. For companies that wish to create a greater diversity of products, custom solutions or customer-focused solutions, AI and robotics can facilitate this, quickly and cheaply.

• Increased Efficiency & Maintenance

Machinery is faster, more accurate and doesn’t feel fatigue in the same way as a human workforce. With some smart factories able to work 24/7/365, it’s clear that the potential to create more for less is real.

Smart sensors have revolutionised the way in which maintenance is conducted, significantly reducing the risk of breakdown and allowing the creation of effective early warning systems.

• Greater Worker Safety

Robots have the ability to work in dangerous or hostile environments. Remotely controlled, they have the potential to remove workers from hazardous situations without compromising the work which needs to be done.

As one of the leading spring manufacturers in the UK, the team at European Springs & Pressings are keen to integrate as many smart technologies into our existing processes as possible. Over the last few years, we have made several changes to our processes and invested in the latest smart technologies to guarantee we continue to meet and exceed our customers’ demands.

Over the years the UK Manufacturing Industry has fallen behind its global counterparts with regards to productivity within the workplace. One of the biggest reasons for this fall in productivity is the skills shortage within the industry. UK based manufacturing businesses need to take action and start to consider upskilling their existing workforce, in order to mitigate the risk of a further decline in productivity across the industry.

Within this article, we will take a deeper look into the current issues faced by the UK manufacturing industry, whilst also offering some solutions you could implement into your business today.

The UK’s Aging Workforce

The aging population in the UK has had a knock-on effect on the UK Labour Market. In 2015 the Chartered Institute of Professional Development (CIPD) and The International Longevity Centre – UK (ILC), conducted a study. This study found that within the manufacturing industry, 33.8% of workers were over the age of 50, this translates to a total 1,041,542 workers.

The manufacturing industry has become increasingly reliant on the more experienced workers, as graduates simply don’t require the skillset required to take over their role. With the current outlook, UK Manufacturing businesses run the risk of developing large skills gaps and losing vital knowledge when the older portion of their workforce inevitably retire over the next 20 years. Without a robust plan in place to ensure that younger workers are upskilled, there are genuine fears over the future of many manufacturing businesses across the UK.

Research from a City & Guilds Group survey conducted in 2019 found some particularly some particularly worrying statistics when it comes to upskilling within the manufacturing industry. Some of the key findings in the report were:

• One in three people working in manufacturing didn’t learn any new workplace skills in 2018.
• 46% of respondents believe they get enough help and support to upskill from their employer.
• 80% of people working in manufacturing believe that it’s important to continuously update their workplace skills regardless of age.
• 48% of respondents feel that the skills they need to carry out their job will change significantly over the next 5 years.

Managing the Risk with Workforce Planning

By introducing a workforce plan, businesses can look to reduce the impact of the skills gap when older workers do eventually leave the industry. The plan you put in place should, at the very least, be able to address the following areas:

• Attracting new talent,
• Line manager capability
• Training & development

The first place you will probably look to plug the ever growing skills gap is by recruiting the right type of employees with a diverse skillset. Building a pipeline of potential employees can ensure that businesses are able to recruit from a diverse labour pool. Whilst you’re probably looking for experienced heads when recruiting solely to fill gaps left by retiring workers, it’s also worth considering how you can fill those gaps with younger workers too. Offering work experience opportunities via building relationships with local schools and colleges, as well as offering apprenticeships are effective in generating new talent, and you never know, you may just find yourself a new employee from utilising these methods.

Beyond recruiting from outside of your business, it’s also important to look internally for any employees who are showing a willingness to learn new skills. The capability of line managers can have a huge impact on the workforce and how they develop. They obviously play an integral role in managing the workforce day-to-day, so they can essentially make or break your plans. Managers should be able to coach workers and develop their knowledge with on the job training whilst also identifying opportunities to undertake formal training for their staff.

Health and wellbeing expectations of workers should be managed and met by Line Managers in a bid to reduce long term absence, as absenteeism can have a huge impact on an organisation. Particularly for the older workforce, where manual jobs can become increasingly more difficult with age, a structured health and wellbeing strategy in place can have a positive impact on workers’ attendance.

It’s extremely important that you educate all employees within your business that both performance management and training and development are not just tick-box exercises. Having a stringent performance management process in place will ensure workers are achieving or even exceeding their objectives, in line with the objectives of the business. Training and development can help employees of all ages to meet their performance objectives, and we can’t place enough emphasis on ensuring that you are consistently looking to upskill all members of staff, regardless of their age. The next big thing could well be just around the corner for the manufacturing industry, so ensuring that all members of staff are fully trained is essential.

Having a management system in place that is capable of identifying and initiating training and development opportunities for employees is an essential part of any plan and is a sure way to ensure that any potential skills gaps are plugged before they appear. Continuous on the job training and coaching as well as formal training will provide workers with the skills and knowledge required to cover absences and keep productivity at its highest when more experienced workers do end up retiring from the industry.

The Benefits of Investing in Automation

We live in an ever changing world, where technology and robotics are becoming more and more present in manufacturing businesses the world over. Young manufacturing workers have a significant advantage when it comes to adapting to any new technologies, simply because they have grown up in a world obsessed with going digital and automation.

Part of the reason why the UK is lower in terms of productivity compared to other manufacturing nations around the world, is simply because of there are less businesses in the UK who have taken the plunge and invested in automated technology. By looking to make investments into new technology and robotics, the UK Manufacturing industry would stand to benefit greatly in terms of productivity. These investments can also generate jobs for younger workers, whilst also opening the door for mechanical and electrical engineering apprenticeship opportunities.

As experienced spring manufacturers, the team here at European Springs & Pressings always take the time to keep a close eye on everything that is going on in the manufacturing industry. We understand just how important it is to ensure we are allowing our valued members of staff to continually upskill, in order to achieve their personal goals, whilst also ensuring the longevity of the industry as a whole. Be sure to regularly check in on our blog for the very latest news coming out of the manufacturing industry.

It’s fair to say that the automotive industry has been through a period of profound change in recent years – with the introduction of a whole host of new technologies into the manufacturing process. Pair the digitisation of the industry with the ever-growing concerns surrounding the environment, and you can begin to see how the future of the automotive sector is so important for a whole host of reasons.

In this article, we take a look at the future of the European automotive sector, whilst also highlighting some of the key trends we expect to see within the next few months.

What Pressures Are Major Car Manufacturers Facing?

Before looking deeper at what the future holds for the European automotive sector, it’s important to study exactly what pressures major car manufacturers are currently facing.

In a new study conducted with over 300 senior executives from automotive giants from around the globe were asked a number of questions surrounding the past, present and future of the automotive industry. Unsurprisingly, the study has thrown up some interesting statistics, including:

• 71% believe they need to adopt Industry 4.0 or digital processes to survive
• 52% of respondents believe a new manufacturer will enter the market with a revolutionary new kind of vehicle
• 69% feel they have never been under as much pressure to innovate as they are today
• 69% believe environmental restrictions on vehicles will become stricter in the coming years
• 65% responded stating they felt consumers would turn against traditional forms of transport in favour of greener alternatives

What Changes Are Just Around The Corner?

More Digitalisation

Digitalisation will continue to play a pivotal role within the European automotive market, with a real focus being placed on investing in more smart factory technologies. IoT and Industry 4.0 are an absolute must for any major automotive company operating in the 21^st century, with the streamlining of existing processes high on the list of priorities for each business.

Many business owners have a genuine belief that if they don’t adopt Industry 4.0 techniques and technologies in the next few years, they will be completely left behind by competitors.

Innovation in terms of products offered and smart working practices will be at the forefront of the automotive industry for years to come, with many consumers looking for alternatives to the current offering available. It will be interesting to see how some of the major players within the European automotive sector deal with the ever-increasing pressure for digitalisation within the workplace, whilst also catering to an ever-increasingly informed customer-base.

 

Focus On Sustainability

Businesses across the globe are placing even more emphasis on sustainability, and there is good reason for this. Whilst steps in the right direction have been taken by several major automotive companies around Europe, there is an opportunity to move towards more sustainable ways of working.

Regardless of the types of changes made by automotive manufacturers, every little really does help. Businesses across a whole host of industries have been taking the steps necessary to have a smaller carbon footprint – but the automotive industry has the chance to have a real impact. The manufacturing process of each car can be streamlined to ensure as little energy is being used, whilst more focus must be placed on using recycled materials in the manufacturing process.

Consumers are more interested in working with and purchasing from companies that are seen to be actively helping to combat global warming, so expect to see a real shift in the way cars are manufactured, along with the materials used in the process, over the coming months and years.

Electric Vehicles

With the focus on sustainability so prominent within the manufacturing process of vehicles, it’s no surprise that vehicles themselves are shifting to more environmentally friendly models. There is a real shift going on within the car manufacturing sector at present, with diesel cars looking to be slowly phased out due to their impact on the environment, electric vehicles are being touted as their long term replacement.

In recent years, there has been a steady rise in the total electric vehicles on UK roads, with around 246,000 plug-in cars registered in the UK as of October 2019. Other countries across Europe have been spearheading the use of electric cars, with the UK some way behind other countries at present.

If car manufacturers are going to tap into this ever-growing market, more must be done to ensure the battery life of electric vehicles continues to improve each year. Alongside this, the Government must also commit to installing more charging points around the UK to ensure that electric vehicles are a viable alternative to petrol and diesel-powered vehicles.

As expert spring manufacturers, the team here at European Springs enjoy keeping a close eye on all of the very latest manufacturing news from around Europe. We will be sure to watch on and see what the future has in store for the European automotive sector! Check in on our blog regularly to keep up-to-date with all of the most important stories from the manufacturing and engineering world.