Category: Engineering

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.

2019 has seen some big changes in both the engineering and manufacturing industries in the UK and around the world, and as the end of the year approaches, now is the perfect opportunity to look back on the trends that have emerged and shaped the sector.

IoT – The Big Thing in 2019

Emerging IoT technology has seen many changes across all industrial sectors in 2019.

IoT (Internet of Things) involves interconnecting unique devices within an existing internet infrastructure to achieve various goals, including improved safety, increased efficiency, product innovation, and meeting compliance requirements.

It’s estimated that around 63% of manufacturers are confident that applying IoT to their systems will increase future profitability. With that in mind, global investment of around $267 billion in IoT is expected by the end of 2020.

IoT provides manufacturers with the capability to make informed strategic decisions using vital real-time data. According to statistics provided by the MPI Group, around 30% of industrial production processes and equipment already incorporate embedded intelligence/smart devices.

Predictive Maintenance Keeps Production On Track

Critical equipment breakdown costs all sectors of the manufacturing industry dearly every year, both in terms of downtime, repairs, and loss of productivity. Therefore, ensuring that all equipment is functioning to its optimum remains a key priority for manufacturers, many of whom are using predictive maintenance tech to do so.

Predictive maintenance tech has been used increasingly during the last few years to reduce the cost of maintenance, lessen unexpected outages, and extend the life of machinery, often by years. This technology monitors equipment by using performance metrics. Through the automation of the data collection process via IoT technology, manufacturers can develop a clearer understanding of how their systems work and when they are likely to fail.

Being able to predict when maintenance is necessary can save manufacturers money, resources, and time. Monitoring tests can be conducted while equipment is in operation, meaning that there’s no loss of production due to equipment shutdown.

Focus Shift From B2B to B2B2C

In 2019, many manufacturers who had an old-school B2B business model have shifted to a B2B2C (business-to-business-to-consumer) model.

The B2B2C model means that buyers get the manufacturer’s retail price, rather than the wholesale price for products, resulting in increased profit. Companies can prototype, test, and bring products to market faster, rather than contending with the lengthy retail sales cycle that insists on locked-down product development far in advance of order and delivery. That gives manufacturers a competitive edge.

Also, selling direct to customers allows manufacturers to collect data that ultimately results in stronger relationships, better products, and increased sales, and is a trend that’s likely to continue into 2020 and beyond.

ERP Systems Work To Streamline Manufacturing Processes

Enterprise Resource Planning (ERP) has increasingly been used in 2019 by manufacturing companies to streamline their processes, creating a lean, competitive advantage.

ERP streamlines processes by providing real-time, accurate information, and automating business operations. That can reduce operational and administrative costs by helping to prevent disruption and delays.

Traditionally, implementing ERP systems has been time-consuming and frustrating for manufacturers. However, 2019 has seen companies using a rapid implementation ERP system, which can be put into operation much faster and more cost-effectively than traditional ERP systems.

3D Printing Makes Production Processes Faster And Cheaper

2019 has seen more and more manufacturers using 3D printing technology in their production processes. Prototyping using 3D printing is quicker and more cost-effective, allowing designers to troubleshoot, change, and test their products much more efficiently.

Also, manufacturers are able to produce individual items on demand, rather than having to produce and warehouse them.

In heavy industry, the process of tooling has traditionally been time-consuming and expensive. However, 3D printing has changed all that. Moulds, fixtures, and jigs that are used in the mass production of heavy equipment have, to some extent, been superseded by 3D printing technology, especially in the automotive and air industries.

Re-Shoring Has Led To More Made In The UK Products

2019 has seen an increase in re-shoring, that is, companies bringing their manufacturing operations back to the UK.

There are multiple factors that contribute to re-shoring. First of all, the economies in many of the most commonly used off-shoring countries are thriving, which has led to wage increases for resident workers, negating the advantage of exporting production processes to these regions from the UK. Secondly, in those countries where labour continues to be expensive, the infrastructures typically are unable to support the most complex manufacturing operations.

Also, transportation costs are increasing, pushing up overheads and reducing the manufacturer’s bottom line. The increased use of new software programmes and robotics has automated many of the processes that were traditionally performed by human workers, which has also contributed to a resurgence in re-shoring.

Industry 4.0: The Fourth Industrial Revolution

2019 saw the take-up of Industry 4.0 within the manufacturing industry. Industry 4.0 superseded Industry 3.0 and is the fourth generation of this technology.

Industry 4.0 has created smart factories, where intelligent robots, AI, and connected machines work alongside more traditional manufacturing technology. To remain Industry 4.0 competitive, manufacturers must identify crucial business needs, build organisational capabilities, actively adapt their business processes and culture so that both remain relevant, and invest in technology.

In 2019, bespoke spring manufacturers European Springs & Pressings acquired a large-scale, 700sq metre powder coating line. That purchase demonstrated the manufacturer’s commitment to the automotive sector and confirmed its position as one of the largest suspension spring producers in Europe.

Embracing Industry 4.0, European Springs & Pressings introduced new software and touch screen systems that improved production line efficiency. The new tech has also improved the quality of the product, doubled throughput, and enhanced process efficiencies. The new technology works alongside new digital response units that enhance and monitor the powder coverage across the spring units.

There’s no doubt that 2019 has seen some big changes to industry and manufacturing across the world. Technology in various formats has been the main driver of change, enabling companies to enjoy greater efficiency of processes, boosting output, and reducing overheads.

It seems likely that 2020 will see even greater changes across many industries, and emerging technologies, including RPA and Natural Language Generation, will undoubtedly contribute to this.

Industry 4.0 is the buzzword of the moment, but there is good reason that so many within the manufacturing industry are constantly talking about it. Whilst everyone is talking about why you should implement Industry 4.0 technologies into your business, you may be wondering exactly what Industry 4.0 is, and how can it benefit your business.

In this article, we take a look at what Industry 4.0 actually is and highlight some of the main reasons that you may want to consider implementing it within your business, sooner rather than later.

What Is Industry 4.0?

In simple terms Industry 4.0 is the fourth industrial revolution, which has seen the use of smart factories, using connected machines and intelligent robots alongside more traditional manufacturing technologies.

There’s no denying it, we are currently in the midst of a digital revolution of how products are produced in the manufacturing industry, with a real focus being placed on smart, autonomous systems that are fuelled by data and machine learning.

What Is The Difference Between Industry 3.0 and 4.0?

Industry 3.0 came about after computers were introduced, and whilst computers have completely revolutionised the way in which businesses work across the world, their initial impact was more troublesome than helpful. However, with a shift from Industry 3.0 to 4.0 well underway, it’s fair to say that the transition has been far more seamless, with the computers now commonly used in manufacturing all being programmed to communicate with one another, allowing them to ultimately make decisions without human intervention.

The Internet of Things and Internet of Systems make Industry 4.0 possible, and as a result of the infrastructure now in place, smart machines are only getting smarter as they get access to an ever-increasing amount of data. As machines gain access to more data, this will result in manufacturing businesses across the world having access to equipment that is capable of increasing productivity, efficiency and decreasing product waste.

Should My Business Invest in Industry 4.0?

Industry 4.0 has already had a profound effect on the manufacturing industry, with many businesses around the world integrating some form of connected machinery or intelligent robots into their manufacturing processes. But there are still a whole host of businesses who are yet to properly integrate smart technologies into their day to day processes; and whilst there are a number of completely valid reasons for this, it is well worth highlighting some of the major benefits that Industry 4.0 can bring to any manufacturing business.

Here are just some of the benefits of incorporating Industry 4.0 into your workplace as soon as possible:

Increased Productivity and Efficiency

Industry 4.0 technologies enable your business and workers to do an awful lot more with significantly less machinery and equipment required. By incorporating smart technologies into your business, you can produce more products in a shorter amount of time, allowing you to meet consumer demand.

In terms of efficiency, smart technologies are capable of automatic track and trace processes and automated reporting, which frees up even more of your employee’s time to ensure your processes are as slick as possible throughout your business.

Along with this, it’s also worth noting that your production lines will experience a significant cut in down times, as machine monitoring enables your employees to intervene as soon as possible if any problems do begin to arise.

Reduce Costs

With increased productivity and efficiency throughout your business, you can be sure you will reap the benefits in terms of cutting costs too. Whilst there are upfront costs you will inevitably face when implementing Industry 4.0 technologies, it’s fair to say that you will see a drastic fall in your overall costs as a result of Industry 4.0 equipment, such as automated technology, systems integration and data management systems.

You may be wondering exactly where the cost reductions will be coming from when it comes to smart technologies: here are just a few examples of potential cost savings:

• Significantly faster manufacturing will increase sales
• Vastly reduced material and product wastage, thanks to improved technology
• Reduced machine downtime ensures your products are consistently being produced
• Reduced operating costs with equipment operating at a far more efficient level
• Virtually no quality issues with products, meaning fewer returns

Whilst it’s fair to say there are a whole host of benefits your business will want to take advantage of, it’s worth noting that these changes will not happen overnight. Properly implementing industry 4.0 technologies into your business takes months of planning and identifying the right types of smart technology that will work for your company. But the team here at European Springs can assure you it is well worth the time and effort, as just last year we invested in an automated pre-stressing machine which enhanced our capabilities as custom spring manufacturers. Since upgrading our equipment, we have seen an upturn in productivity, allowing us to better serve our valued customers.

Over the past few years, UK manufacturers have surged well ahead of other countries in terms of sustainable manufacturing. This uptake in taking more accountability when it comes to environmentally friendly practices came about after the Government introduced initiatives such as the Climate Change Levy, which provided incentives to manufacturers who stuck to tight energy efficiency rules.

Despite manufacturing businesses in the UK being well ahead of other countries around the world there are actually more than 70% of UK manufacturers who admit that sustainability is not one of their key business priorities. With that in mind, we delve deeper into what can be done to improve manufacturers commitment to sustainability.

What Can Manufacturers Do to Improve Sustainability?

The importance of sustainability cannot be understated within the manufacturing industry, with the sector providing 44% of the UK’s total exports. With the manufacturing sector taking up such a large proportion of all UK trade, any improvements that can be made to the overall environmental impact of the industry should definitely be considered.

Here, we take a look at a number of changes that your business can implement almost immediately to ensure you become more sustainable in the coming months and years.

Start Small

If you haven’t really considered how you can make your business more sustainable before, then the best advice we can give you is to start small. Every change you make has a massive impact over time, so don’t ever underestimate just how important it is to even just turn off the light as you leave the room.

When you have started making a habit of those smaller sustainability changes within your business, you’ll find the bigger changes are an awful lot easier to integrate into your employees normal working day.

Assess Your Current Energy Usage

Carrying out a full survey of your company’s energy usage, from offices to manufacturing equipment, is a fantastic way to ensure you are working in the most environmentally friendly way possible. From the energy survey, you may find there are obvious areas of your business that are using far more energy than you probably should be.

Not only are you becoming a more sustainable business from making changes to your energy consumption, but you will also see a reduction in your energy bills over time too. It’s well worth considering your energy consumption as it can often be something you can change immediately providing you have the infrastructure in place.

Identify and Implement New Materials

If you are really serious about upping your sustainability game, then assessing the materials that are currently being used to create your products is a great place to make changes. Whilst this won’t be possible for every manufacturing company, there are a whole host of businesses who will almost definitely be able to start using more environmentally friendly alternatives in their processes.

 

Form Partnerships With Environmentally Conscious Partner

Forming partnerships with like-minded businesses who are also concerned about sustainability within the manufacturing sector is a fantastic way to ensure your business is doing everything within its power to be environmentally friendly. By sourcing environmentally friendly materials from other sustainability focused businesses is a fantastic way to ensure you are doing your upmost for the environment.

It’s also worth noting that forming a partnership with other eco-friendly businesses is great for brand awareness and highlights your commitment to all things sustainable. With more and more business leaders seeing the importance of preserving the environment, this could see more clients heading your way in the coming months.

Encourage Recycling

It goes without saying that you should definitely consider actively encouraging your employees to recycle where possible. Introducing recycling points around your business is a simple fix for any general waste that your employees may have – but you could also consider taking a closer look at any waste products from your manufacturing processes and implementing clear recycling processes for them.

It’s fair to assume that nearly all manufacturing businesses will have a whole lot of excess and wastage following the completion of each product, so recycling any off cuts can make a huge difference to the environment as a whole.

Update Your Equipment and Machinery

Any old equipment and machinery that is consistently being used as part of your day to day business operation can actually be extremely harmful for your sustainability rating as a business. This is down to older machinery and equipment being far less energy efficient than updated models; not only are they worse for the environment, but they are usually less efficient in terms of productivity too.

Whilst the initial investment in new equipment and machinery may seem excessive, you are sure to make your money back over time in terms of energy savings and increased productivity for your business.

As expert spring manufacturers in the UK, we take great pride in our commitment to ensuring our processes are all as sustainable as possible. Over the years, we have implemented a number of new internal processes and have invested heavily in new machinery to ensure we are working in the most environmentally friendly way as possible.

Ensuring that young people are engaged and interested in engineering topics is more important than ever before. With the skills gap becoming an increasing issue within the engineering and manufacturing industry, educational institutions around the country need to take action immediately.

In this article, we take a look at some of the reasons that we need to encourage more students to become engineers, as well as some tips on how to get young people engaging with the engineering industry from a younger age.

Why Do Young People Need To Be Engaged By Engineering?

Over the last few years, the skills gap between older and experienced workers and university/apprenticeship graduates has grown significantly. With an ever-increasing demand for highly skilled workers within the engineering industry, extreme strain has been put on employers and budding engineers.

The expectation from employers is that young employees must come in and begin working at a level far beyond their years of experience, the current model simply isn’t sustainable, with older and experienced engineers edging ever closer to retirement. According to research carried out by EngineeringUK, the UK will require 203,000 people with Level 3 Engineering skills each year to meet demand through to 2024.

It’s also worth noting that there are several under-represented groups in engineering and steps need to be taken to address these gaps. Research carried out in 2018 by EngineeringUK found that just 12% of the engineering workforce is female, which presents a huge challenge as we try and encourage more young women to join the engineering workforce.

There are also huge challenges with representation from ethnic minorities within engineering, with just 9% of the current workforce made up of individuals who are of minority ethnic heritage.

How To Engage Young People In Engineering

With so much emphasis being placed on ensuring more young people from all backgrounds become engaged with the engineering industry and choose to take up a career within the sector, it can be difficult to know exactly how is best to approach workshops, lessons or talks on the subject. From including hands-on activities within your session to highlighting the benefits of working within the engineering industry, here are some of our top tips on how to create engaging workshops on engineering for young people.

• Make tasks applicable to young people – When a young person thinks about a job in engineering, they can be forgiven for believing it is most likely out of their reach. Create tasks which highlight they already possess a whole host of applicable skills such as teamwork, communication, problem-solving, logic, creativity, perseverance, and learning from their mistakes.
• Highlight failure as a positive – Many young people believe that failure is negative and should be avoided at all costs, but in engineering, failure is a key part of the process to creating a new product. Activities centred around bouncing back from failure are a vital part of engaging young people with engineering and should be included in any workshop.
• Get hands-on – It’s fair to say that the vast majority of young people dislike the idea of being talked at for an hour about a subject they are unfamiliar with, so be sure to include activities that engage with young people. Group activities are extremely effective and resonate with most young people, as they solidify learning and create a buzz around the group, which can be talked about over the coming days and weeks.
• Highlight benefits of working within engineering – One of the most important parts of any engineering activity is highlighting the many benefits of working within the industry. Here’s just a selection of benefits you could choose to highlight: pay, opportunities to travel, career prospects, working in a varied and fast-paced environment and making a positive contribution to society.
• Create awareness of different industries within engineering – Engineering is a vast and diverse sector, with opportunities to work in various industries within engineering. Some of the lesser-known industries within the sector include entertainment, power, the environment, food and drink and even sport.

Here at European Springs and Pressings, we pride ourselves on ensuring young people have a clear pathway into the engineering industry. Over the years, we have run several apprenticeship programmes, which have led to apprentices securing full-time roles within engineering companies upon completion. We believe that imparting our knowledge as an industry-leading spring manufacturer to young people is imperative to the survival of the engineering industry as a whole.