Through life engineering

Innovation will be key to the speed of the global recovery from the COVID-19 pandemic and will shape the development of the manufacturing industry both now, and in perpetuity. Indeed, it was the work of pioneering manufacturers and engineers which first offered hope in the treatment of coronavirus-stricken patients.

The UK Ventilator Challenge, led by Dick Elsy, CEO of High Value Manufacturing Catapult, saw a consortium of manufacturers, motorsport firms and engineers collaborate like never before to ramp up production of vital ventilators at a time of national emergency. Other manufacturers were also involved, modifying their processes so they were able to produce PPE equipment, such as face masks, for the NHS.

The spirit of innovation at a time of crisis also led to the development in record time of effective vaccines that are helping to combat the spread of the deadly disease to more manageable proportions, helping us recover some degree of normality.

The MTA prides itself on its advocacy of such work. This is why innovation is consistently celebrated at its MACH Exhibition. MACH is a content-led event that brings together the latest advanced engineering and manufacturing technologies in operation all under one roof. Highlights for next year will include a significant focus on the digital factory, with more automation and connected manufacturing processes, power-by-the-hour and new cost efficiency solutions that will dramatically improve production processes and help shape the industry over the next decade.

MACH has always been the place to see real innovation come to life. Manufacturers and engineers come out in force to support the UK’s national show and see first-hand how technology is developing. Such will be the case when the National Exhibition Centre in Birmingham opens its doors once again to the UK’s manufacturing show in September 2022.

It is a desire to develop ever more innovative and effective processes that drive many manufacturers forward. Seeking the elusive process that will help improve their competitiveness in the global marketplace is precious and it is why innovation is rightly considered to be the lifeblood of the manufacturing industry.

Maximise availability

One of the most effective systems developed in recent times has been Through-life Engineering Services (TES). TES relates to design, manufacture, maintenance and technical support of complex engineering products throughout their lifecycle. TES uses high quality information to maximise the availability, predictability and reliability of such products at the lowest possible cost.

TES is gaining in significance because it impacts on every stage of a product's life. Built-in obsolescence, for so long the mainstay of consumer goods, is no longer a viable model. Customers of high value complex products no longer want to bear the burden of short-term life cycles.

The costs involved in the design, development and manufacture of products such as aeroplanes, ships, trains and machining tools are considerable, not least because of the research and development work that has gone into producing such machines.

A more sustainable ownership model has long been desired, and this is now embodied by the TES offer. The purchase of such high value complex items is not undertaken lightly, even for vast multi-national customers such as airlines and marine freight operators. Many of these companies opt for a leasing model that allows them to pay for their safe reliable use of such products rather than bear the cost of outright ownership.

Such an approach has many advantages. A whole-life engineering support plan offers manufacturers long-term customer relationships and access to other revenue streams.

Aero engines

Whilst in the future, a TES-style model has great potential for products such as cars, white goods and buildings, the process is currently achieving strong results for manufacturers such as Rolls-Royce Aerospace.

The aero engine manufacturer has been pioneering the through-life package for some time, to positive results. Whilst the pandemic has severely impacted the aviation sector, with long-term deals for new aircraft put on hold or cancelled altogether, the is TES that continues to offer hope for the sector.

To offset the cost of outright ownership, Rolls-Royce customers prefer to pay the company for the ‘hire’ of an engine. In this way, the risk to operators is minimised as ownership rests with a bank or other investor. The system offers customers peace of mind as they know their operations are predictable, or at least they were prior to the pandemic.

Whilst the aviation sector – as with so many other sectors - is in a slump currently, it is still predicted to recover. Not surprisingly therefore, other companies have been quick to cease on the advantages of TES models and more of their revenues are being derived from such sources.

New products are being designed with an added emphasis on improved reliability and longevity, supported by the ability to machine-learn and utilise data gathered from previous uses.

The technology enables individual components to be tagged and sensor systems embedded to capture specific intelligence. This enables a manufacturer to consistently monitor the performance of a product throughout its working life, with predictable maintenance, repair and replacement being undertaken long before a product fails.

The flexibility of the system allows manufacturers to supply product upgrades over the lifecycle of a product and in this way, improve its durability and performance. This extends a product's useable life, whilst reducing the lifetime cost. The intelligence gathered during the process also helps to indicate when certain parts are ready for disposal.

As sensors become more sophisticated and the use of automation and robotics more widespread, so the manufacturing process is made more efficient and sustainable.

Market advantage

Estimates prior to the pandemic were that the global market for TES could be worth £1 trillion by 2025. Opportunities for the UK manufacturing sector are therefore considerable, and effective innovation and education – both skills advocated by the MTA – could see the UK gain significant market advantage.

The MTA is not alone in its advocacy. Bodies like the High Value Manufacturing Catapult (HVMC) are helping to outline how the technology could translate into other sectors, in turning helping to generate thousands of new jobs in high value, engineering sectors.

This is why these processes are key to the UK’s long-term economic wellbeing and why such technologies are rightly celebrated at the MACH Exhibition.
We look forward to seeing you there.