THERE IS currently a great deal of talk throughout the industrial sector about digital transformation and the benefits that come with it. By implementing higher degrees of automation, production sites can keep running 24/7, with little or no human involvement needed. 

Through this lights out manufacturing, such sites can achieve elevated productivity levels. This approach can also remove human errors, improve yields and dramatically reduce the likelihood of product returns - thereby bolstering profit margins and improving brand reputation.

In terms of managing overall operations, the advanced network infrastructure now being rolled out within factories is enabling access to unprecedented quantities of data, with valuable insight subsequently being gained. The upshot of this is that workflows can be examined to find where improvements might be made - leading to boosts in throughput, better product quality, less wastage and heightened energy efficiency.

Availability of a greater wealth of relevant information also opens up opportunities for predictive maintenance, which allows an understanding of equipment at a granular level. Any functional issues impinging on the production capacity can be identified and defective parts pinpointed (then repaired or replaced). The working lifespan of equipment can be extended and unwanted downtime safeguarded against.

Going even further, digital twins of machinery or even whole factories can be constructed from compiled data. Using these virtual equivalents, different scenarios could then be played out - instead of having to do tests on actual equipment (where there would be a risk of it being damaged). The implications may then be ascertained by running machinery faster or conducting a process with different parameters (heat, pressure, etc.) applied.
 
Making the dream a reality

Although this all sounds exciting, bringing it to fruition is not necessarily that simple. Often there is a dislocation between the information technology (IT) aspect of a factory, that manages the processes, and the operation technology (OT) aspect, which is responsible for controlling and monitoring all the equipment. On the IT side, data is transferred through high-speed Ethernet networks. Computing hardware and servers have relatively short replacement cycles and this has accelerated technological evolution here. In contrast, on the factory floor things move at a slower pace, making the situation a lot more complicated.

Factory facilities will be filled with turning equipment, drives, presses, conveyors and suchlike that may have all been fitted a long time in the past - before the emergence of the Industry 4.0 era, when value of ongoing data collection was not understood. In general, such machinery will still be dependent upon programmable logic controllers (PLCs). These units, which form the foundation of companies’ OT implementations, can easily be one or two decades old, in some cases even older.

If the many advantages associated with data-driven production are to be realised, then factory operations managers need an effective strategy. Carrying out large-scale upgrading of equipment throughout a facility will prove completely impractical - not only due to the financial outlay required, but also the time it would take and the interference caused to production workflows. Retrofitting extra functionality onto legacy equipment presents a much more cost-effective and less disruptive approach, so previous capital investments are not wasted. Here are some of the factors that need to be considered.

Sensing 

IoT-based smart sensors can be placed onto items of equipment for monitoring purposes. They can measure vibrations emanating from such equipment, as well as checking that temperatures do not exceed certain predefined levels - thus helping with predictive maintenance. Data captured may then be wirelessly transmitted to an operations management system within the IT domain. Smart sensors are relatively easy to deploy, not requiring wireline infrastructure. They can run off batteries, or even draw power from vibrations or thermal gradients via energy harvesting.  

Connectivity

Having acquired data, there must then be scope for passing it from sensor devices within the factory back to a centralised hub or to the cloud. PLCs utilise different fieldbus protocols (such as MODBUS, ProfiBus, EtherCAT, ControlNet, Profinet, etc.) or possibly proprietary mechanisms for interfacing with equipment. The IT side and higher levels of the OT side of a factory operation will, however, rely on Ethernet connectivity. In order for data from these PLCs to be utilised, a suitable form of conversion is mandated.

HMI

There is also the prospect of augmenting operative interaction - by adding touch-enabled human machine interface (HMI) functionality. This will provide a far more effective alternative to the outdated push buttons and hexadecimal displays normally found on PLCs. Such enhancements can be done via serial interconnections (RS-232 or RS-485) or USB interfacing.
 
Sourcing optimised solutions

By engaging with the team at EU Automation - and drawing on their expertise in supplying new, reconditioned and obsolete parts - factory managers are assured of receiving the support that digital transformation of their facilities will require. They will be able to get hold of the technology necessary for them to make the most of already deployed equipment yet still implement next generation functionality. The sensing, connectivity and HMI aspects previously discussed are all covered.

There are numerous retro-fit HMIs available from EU Automation. Different screen sizes can be chosen from, with ruggedized versions offered for deployment in more extreme industrial environments. One example is Mitsubishi Electric’s GOT HMI product family, which supports multi-touch gesture recognition. These units have capacious memory resources, plus the convenience of USB interfacing.

For increasing data availability, the Siemens 6ES5 470-4UC12 is an analogue output module for Simatic S5 PLCs. Its eight outputs convert the PLC’s digital signals into the analogue format that process analysis calls for. The modular design makes it easy to adapt to particular application requirements. 

Using Mitsubishi Electric’s UC232A USB-RS232 adapter, hardware based on RS-232 connectivity can interface with USB. This solution features a standard DB-9 male connector and a USB Type-A connector, plus a 35cm cable. Control Techniques’ USBRS4500-0096 adapter provides USB to RS-485 conversion, with USB and RJ45 connections and a 1.2m cable. The connectors and cabling are IP54 rated, to protect against liquid ingress. An -20°C to +40°C operational temperature range is supported.  

As well as being applicable for integration with modern equipment (via Ethernet, PCI, DisplayPort, SATA, etc.) Mitsubishi Electric’s MELIPC can use its serial connectivity (RS-232, RS-422, RS-485) to transfer data to/from legacy hardware. Its multiple Ethernet ports mean that enterprise (IT) and factory floor (OT) networks can be kept completely separate from one another - resulting in better protection against security breaches.     

Since legacy equipment will feature cyber protection mechanisms that would prevent data being accessed, methods are needed that will allow such mechanisms to be circumvented. For example, PTC’s ThingWorx IIoT software provides a common communication network between new and legacy hardware. 

Alongside this array of products, EU Automation can also take care of reconditioned and refurbishment work. As a result, obsolete PLC devices from suppliers like Schneider Electric and Omron can be updated.

Conclusion 

It is clear that completely upgrading a facility with the latest equipment would constitute engineering effort and expense far beyond most companies’ budgets, as well as holding up production activities while such work is being done. Consequently, factory operations managers will be reticent about taking such an approach. Nevertheless, they want to be in a position to fully leverage all the data available to them and move closer towards their long-term objective of end-to-end automation. This calls for more nuanced tactics, where technology for different eras is able to work together with maximum effectiveness. 

For more information: 

www.euautomation.com

Tel: 01785 303300

CUSTOMISATION AND high-mix low-volume (HMLV) production are not new concepts in manufacturing. Both have risen to prominence in the last decade, with the demand for increasingly personalised products and services. These trends require manufacturers to rapidly adapt to changing market conditions, and to reconfigure their production and assembly lines accordingly.

The need for adaptability intensified during the pandemic, when many production plants experienced a boom in demand and needed to set up extra lines to produce critical supplies such as respirator components and personal protection equipment (PPE). On the other hand, some companies needed the flexibility to switch their production to entirely new items — from alcoholic drinks to hand sanitiser, from luxury fashion to medical gowns. 

The solution in a nutshell

In this context, closed-loop automation cells have become increasingly popular. Automation cells, or robot cells as they are often called, are closed systems containing equipment that can automate several stages of the production process. For example, they may include robotic arms that load and unload the parts to be machined, in-feed and out-feed conveyors, and machine vision systems that determine what part is being fed-in, and that measure and inspect post-processed items.   

Compared to traditional production lines, automation cells offer unprecedented flexibility. Since the days of factory pioneer Henry Ford, manufacturing plants have worked in a similar way — with long, linear production lines where items pass from station to station, being processed and finally inspected and shipped. In these lines, every change requires the intervention of multiple experts and can lead to several weeks of expensive downtime.

On the other hand, automation cells allow for a modular and easily scalable factory structure. These cells can be quickly rearranged on the factory floor whenever manufacturers need to restructure the production process — some models even come on wheels. 

Another great advantage of automation cells is that they can be placed in any building where there is enough floor space. This means facilities like empty warehouses can be easily repurposed to set up a new production plant in record times. 

This approach is perfect for manufacturers that need to establish a new production line very quickly, for example to respond to a sudden surge in demand. However, it will also facilitate those who are planning to bring production closer to the final customer to save on logistics costs, reduce lead time and minimise the company’s overall carbon footprint.

For example, British electric vehicles (EVs) start-up Arrival uses flexible automation cells in its microfactories, which are small-scale production plants that the company is planning to set up on the outskirts of cities worldwide. The use of automation cells allows the company to set up new production lines very quickly, so instead of relying on production sites overseas, Arrival has chosen this innovative approach to reduce costs by bringing production closer to where its vehicles are needed.

A further advantage of automation cells is that a factory structured this way can be very easily scaled up and down according to market demand, by simply adding or subtracting cells. This is a great approach for start-ups and smaller manufacturing companies who might not be in the position to invest in a huge and cost-prohibitive facility but want to give themselves space to grow. 

A look within — standard components

The beauty of automation cells is that they contain everything the plant needs to automate the production process — or at least some of its core aspects — in an extremely compact architecture. Like Lego building blocks, the components in the cells are structured so that they all fit together to occupy the least possible space. 

This is leading to an interesting phenomenon in equipment manufacturing — the standardisation of automation machinery. Traditionally, production and assembly lines were bespoke projects that required the expertise of several high-skilled professionals, such as design engineers and systems integrators. Designing, building and testing the line took several months, was extremely expensive, and required long periods of downtime. 

On the other hand, automation cells can be realised in less than one week, although up to three weeks may be needed to map out the necessary tasks within the cell and establish the optimal workflow. There are even useful digital tools to help users in the process. For example, FANUC’s Build Your Cell configurator guides users at every step to create the ideal cell for their application. 

The benefits of automation cells are clear — production can start shortly after the manufacturer perceives the need for new workstations, either because of unprecedented demand, or because of the necessity to adapt production to new specifications. As well as this, costs are minimised and the overall agility of the plant is increased. 

It seems clear that manufacturing is evolving from an industry based on cumbersome, bespoke projects to one that requires extreme flexibility through the use of modular architectures and standardised components. Automation cells offer a great chance to innovate manufacturers’ business models and keep up with the ever-evolving needs of an increasingly demanding global market. 

Neil Ballinger is head of EMEA at EU Automation

For more information: 

www.euautomation.com

Tel: 01785 303300

It’s a well-known fact that prevention is better than cure. When it comes to industrial equipment, emergency repairs are notorious for causing extended unplanned downtime, so tackling problems before they occur is generally seen as the best approach. However, there is a big difference between preventive and predictive strategies.

According to a new report published by maintenance specialist Senseye, manufacturers experience an average of 27 hours of downtime a month because of equipment failure, resulting in multi-million revenue losses by the end of the year.

With manufacturers striving to cope with rising competition, rapidly changing consumer trends and an unprecedented pressure to deliver high-quality products quickly, these losses can seriously compromise business’ bottom lines. 

Taking care of existing equipment is one of the most effective ways for manufacturers to minimise costs while delivering on customers’ expectations. As Darren Halford writes in EU Automation’s BoOM – The Book of Obsolescence Management, which can be downloaded from our website: “There is an old adage in Britain that goes if it ain’t broke, don’t fix it. It means you shouldn’t tamper with things if they are running smoothly. If we want innovation to prevail, this proverb shouldn’t be taken literally. Although it might seem counterintuitive, sometimes the best option is to maintain the status quo. This is often also the most cost-effective solution.”

Historical vs real-time data

Preventive — or preventative — and predictive maintenance are often used interchangeably to refer to maintenance strategies that allow manufacturers to act before equipment fails. Both methods are vastly superior to reactive maintenance, where equipment is run to failure until emergency repairs are needed.

However, preventive and predictive are not the same thing. Preventive maintenance involves carrying out checks at regular intervals, regardless of the equipment’s condition. It relies on best practice guidelines and historical data to give plant managers the best chances to keep machines in good repair, but requires cyclical planned downtime. Moreover, planned checks might be scheduled too infrequently or too late to react to sudden changes in the equipment’s condition, meaning that this method might not always succeed in spotting problems in a timely manner.

On the other hand, predictive maintenance occurs only when needed, relying on real-time data from IIoT-connected equipment to identify potential threats before it’s too late. In this way, repairs address an actual problem and are more targeted, meaning that downtime, when required, will be generally shorter compared to other maintenance methods. The use of real-time data also means that manufacturers can react almost instantly to potential threats. 

As competition increases and manufacturers struggle to keep up with rapidly changing trends, predictive maintenance can be a blessing. As Jim Davison, region director of the South of England at Make UK, recently commented: “predictive maintenance can play a crucial role in not only reducing costs, but also boosting productivity at a time when manufacturers need to be using every tool at their disposal to meet the demands of an ever-changing industry.”  

The problem with big data

Predictive maintenance has clear advantages, but relies on technologies for continuously monitoring equipment and gather valuable data — an approach also known as condition-based maintenance. While the devices to collect data can be relatively inexpensive and easy to set up, processing that data to draw relevant information on the machines’ health is the challenging part. 

IBM estimates that about 90% of all data generated by sensors never get used. This means that manufacturers miss opportunities to make informed decisions about their equipment, while still paying to collect and store unused data. Data that are collected but not processed or used in any way are known as dark data and represent a huge challenge for the industry. 

Dark data can offer manufacturers an untapped resource for potential insight, or may be a costly waste of space, which is why enforcing data policies and training staff on the handling and analysis of data is the first step to manage this information more effectively.

Another issue with big data is the presence of data silos, where data is processed and relevant patterns are discovered, but the resulting insights are not shared among the different departments of an organisation. This can happen because the business doesn’t have the necessary technology in place for data visibility, for example it might lack a unified integrated data management (IDM) tool, and every team might rely on different platforms. 

For example, data suggesting that an electric motor is overheating might be available, but if the C-suite don’t share it with the maintenance team on the production floor in a timely manner, the motor might be doomed to failure. 

Technology that helps

Having sensors to gather significant information on your equipment is the first step to incorporate predictive technique into your maintenance strategy. Recent machines normally come with a variety of options for real-time data acquisition, but legacy equipment can also be retrofitted with inexpensive add-on sensors. 

As a matter of facts, predictive maintenance can be a huge help when dealing with aging assets, which require careful planning when sourcing obsolete spare parts. Retrofitting older assets offers the possibility to not only keep machinery in operation for longer, but also to improve operations by collecting data that could be used for process optimisation.  

However, the impressive amount of dark data in the industry, coupled with the pervasive issue of data silos, shows that gathering data is not enough. To predict equipment failure effectively, manufacturers should implement technologies that facilitate real-time data processing and that allow all relevant personnel to have access to the resulting insights.

In this sense, edge computing can be a valuable solution. One of the problems with data from industrial equipment is that the older it gets, the less relevant and accurate it becomes. By analysing data as close as possible to the source, rather than sending it all to the cloud, edge computing minimises latency and supports real-time decision making.

Edge computing can also help deal with another issue that comes with connecting more equipment to the IIoT — cybersecurity. When data travels back and forth from the cloud, there is an increased risk that it might be compromised. Processing data closer to the source reduces this risk, offering the advantages of increased digitalisation without opening up more potential attack surfaces. This doesn’t mean that processing or storing data in the cloud should be avoided at all costs, but simply that the two options can go hand in hand to maximise results.

Another priority should be the convergence of information technology (IT) and operational technology (OT). These used to be managed by separate teams with different skillsets, but the increased digitalisation of manufacturing processes, including maintenance, means that there is now the need to bring these areas together. OT collects raw data from PLCs, motors, sensors and other key equipment, while IT gives the data meaning by uncovering relevant patterns. However, for this to work, both equipment and teams must communicate and collaborate proactively.

Implementing technology for data acquisition and processing can require a sizable initial investment and, most importantly, a radical cultural shift in manufacturing plants. However, the results in term of reduced downtime and increased efficiency will give manufacturers the competitive edge they need to prosper in an increasingly digitalised world.

Neil Ballinger is head of EMEA at EU Automation
www.euautomation.com/uk

IN 1834, the Prussian engineer Moritz Jacobi innovated the first real rotating electric motors that successfully generated mechanical output power. After four years, he created another motor that could power a boat with 14 people on board across a wide river. Skip to today and electric motors are found in almost everything, from the vacuum cleaners and dishwashers we use at home, to fans, pumps, blowers and turbines in manufacturing plants. A wide range of motors are designed and constructed to work in hazardous locations or harsh environment such as chemical plants, pulp and paper mills and foundries – where maintenance can be very challenging.

Protection from contaminants

Motors operating in hazardous areas are highly exposed to damaging pollutants, including excessive moisture, electrically conductive dust, chemical fumes, explosive gases and more. To protect the working components of the motor, an enclosure can be used. There are many types of enclosures, each offering different levels of protection and cooling. The ones that are generally used for hazardous area motors and heavy-duty motors include explosion-proof (XP) enclosures, dust-ignition-proof enclosures and totally enclosed fan-cooled (TEFC) enclosures.

XP enclosures are designed to contain an internal explosion of a specified hazardous substance inside the motor without igniting flammable gases or particles surrounding the motor. The maintenance of XP enclosures can present several challenges. Since these enclosures are used in corrosive atmospheres, materials including stainless steel or bronze need to be used. The cable entries also require a specific arrangement, which includes reductions, cable clamps, conduits and so on. The use of these particular materials and items may cause high maintenance costs. Furthermore, the safety level of XP enclosures highly depends on their proper maintenance by the plant personnel.

Motors with a TEFC enclosure have exterior surfaces that are cooled by an external fan on the motor shaft. They are widely adopted in dusty, dirty, and corrosive atmospheres. In terms of maintenance, it’s necessary to keep the motor clean to minimise heat transfer. Also, the internal temperature of the motor always needs to be kept higher than the surrounding environment to prevent condensation from forming inside the motor, which may corrode the windings.

Overheating

Particularly for motors operating in areas with extreme temperatures, excessive heat may seriously deteriorate both the winding insultation and the bearings. Moreover, contamination from dust and debris and high levels of vibration could increase the internal temperature of a motor to an unsafe level. Additionally, motors running at higher altitudes might be more likely to suffer from overheating, because reduced air pressure and density can cause larger temperature swings.

To avoid these issues, thorough and regular maintenance is needed. Manufacturers could install smart sensors to detect a motor’s temperature in real time and receive an alert before the motor’s temperature reaches a dangerous threshold. Since the lack of ventilation is also a problem, manufacturers need to ensure that the ventilation holes are clear, and that fans are working properly. In liquid cooled motors, it’s important to regularly monitor coolant levels and to top up when necessary.

Compliance

According to the new EU ecodesign regulation, from 1 July, motors for special purposes rated from 0.75kW to 1MW must reach an efficiency level of at least IE3. The new directives don’t mean that manufacturers in the EU need to replace their existing motors, but that all the new hazardous area motors they purchase from now on must be rated IE3 or higher.

The malfunctions of motors operating in harsh conditions are frustrating, as they cause unexpected hazards and downtime, which adversely affect businesses’ bottom lines. EU Automation offers a comprehensive supply of electric motors for operations in harsh conditions.

Neil Ballinger is head of EMEA at EU Automation

www.euautomation.com

Challenging working conditions require innovative and effective solutions, one being remote condition monitoring (RCM) for industrial equipment. Remote condition monitoring is the ability to view the performance, status and behaviour of a machine from a distance in real time. This is achieved with a combination of Internet of Things (IoT) technology and cloud computing that allows an on-site machine to be tracked by maintenance engineers wherever they are.

How does RCM work?

To be effective, RCM uses three key components — stable connectivity to collect data, a platform to process and store them, and tools to present them to engineers.

Firstly, sensors are being attached to the plant equipment to continuously relay vast amounts of data. The latest machinery comes equipped with such sensors, but for older assets, these sensors can be added into the existing structures. Collecting data requires a standardised industrial connectivity that can support an Industrial IoT platform. The platform establishes a secure connection between the machines and the sensors and provides real-time notifications alerts and cloud storing services.

After data is collected, it needs to be stored and processed accordingly. The metrics are sent to the cloud and stored on the IoT platform to be transformed into actionable information.

Finally, this information is delivered through dashboard applications or mobile notifications to a maintenance engineer. Remote monitoring solutions using the latest applications will also leverage additional features, such as intelligent queuing or routing of notifications, geospatial directions of the asset or even service instructions. From here onwards,  if engineers detect a problem in one of the machines, they can perform root cause analysis, order replacement parts, and direct the maintenance team, all from the comfort of their own houses.

Added benefits of augmented reality

In recent months, large corporations have trialled virtual reality headsets for meetings to give people the impression they sat next to each other. The challenge for maintenance engineers is not only to find a suitable remote working environment, but also to train future engineers for the growing demand in the field. Augmented reality (AR) could replace face to face training and deliver innovative experiences for workers to develop their skills.

Regardless of their location, workers can come together in a virtual setting and share information, while also tracking their work progress in real time. Not only could workers step into a virtual training session, but their work on analysing large amounts of data can be simplified by presenting the data in a visual form, regardless of where they are and what they are doing. For example, as the workplan appears before their eyes, it can be analysed while walking the dog or enjoying a sunny day in the garden.

Thanks to RCM and augmented reality, potential problems can be spotted early on and replacement parts can be ordered before failures can cause downtime and generate financial loss. EU Automation supplies new, reconditioned and obsolete automation and control parts quickly anywhere in the world. This way a maintenance engineer in the United Kingdom could, for example, assist a machine in a plant in Australia in the quickest time. Not only would this reduce downtime, it would also mean experts all over the world could help each other and share knowledge.

While solutions like remote condition monitoring and augmented reality may seem farfetched, the changing conditions of remote working could make them a reality in the near future. For maintenance engineers, such solutions could ensure they are able to do their job from the comfort and safety of their own houses.

Ballinger is head of EMEA at EU Automation

www.euautomation.com

IN HIS 2004 book The Paradox of Choice — Why More is Less, American psychologist Berry Schwartz argued that reducing the number of choices greatly reduces anxiety for consumers. Schwartz’s thesis has been corroborated by a wide number of studies, showing that an excess of options can make people feel confused and overwhelmed.

This is the situation facing many manufacturers trying to integrate AI in their production lines. Though aware of the operational benefits of AI, small to medium enterprises (SMEs) might be deterred by the cost of proprietary software, its complexity and, last but not least, the sheer abundance on the market.

Most companies just don’t have the time and resources to spend researching every available tool until they find the one that meets their needs. Once a decision has been made, manufacturers might face yet another hurdle; purchasing exciting new technologies only to find out that they can’t communicate with each other.

Cost and complexity of integration are not the only challenges — lack of skills is another common headache. When graduates enter the job market, they are often faced with myriads of software that they are not familiar with, because the education system cannot possibly keep pace with the number of solutions on the market.

Over time, these barriers stifle progress and hinder a more widespread deployment of AI-based systems.

The open-source revolution

To overcome the challenges posed by proprietary software, more and more AI solution providers are embracing an open-source culture. Making software freely available to a wide number of users has advantages that, over time, can make this model more profitable than keeping algorithms and data protected by copyright.

For example, in 2019 Goldman Sachs released some of the code that its traders use to analyse and manage risk on GitHub and offered additional funding to engineers who managed to build new applications using the code. The benefits of making the code available to the public far outweighed those of keeping it secret — not only can users help improve and finetune the code, Goldman Sachs will also own the intellectual property of any application built using it. It will also have the chance to be an early investor in new and promising technology.

Recently, a growing number of tech companies have supported the open-source movement to help democratise access to AI and spur innovation. Google, for example, opened up its machine learning framework, Tensorflow, in 2015. More recently, Facebook has made DeepFocus, its AI-based framework for virtual reality technologies, available to the public.

As the examples set by these tech giants suggest, open source is revolutionising the world of AI. By removing current barriers such as costly fees, complexity of integration and the skills shortage, AI providers are allowing more and more companies to see AI not as the exclusive domain of global corporations, but as something that even SMEs can approach.

To learn more about the future of AI in manufacturing, visit EU Automation’s Knowledge Hub at: www.euautomation.com/uk/knowledge-hub/artificial-intelligence

Neil Ballinger is head of EMEA at EU Automation

Communication is key in business, so when the recent pandemic resulted in more people working from home, businesses had to find a way to stay connected. Video conferencing platforms seemed most popular – Zoom, for example, saw daily traffic increase by 535% and reported 200 million meeting participants daily in March 2020.

Remote working in the long term, however, takes more than choosing a good video conferencing platform. Businesses must consider how their team can effectively and securely access content from multiple environments. Every business will have a different set up, for example employees might use corporate laptops or personal devices. Employers should consider the best environment for their team. For example, should they host a server that employees access using a VPN, store data using a cloud-based environment and access content on shared platforms such as Google Drive or Microsoft Teams?

Will offices become obsolete?

As more businesses embrace remote working and less people are in the office at any one time, employers may reduce available workstations and office space. However, businesses should not remove private workspaces all together. Remote working can improve productivity, but employers should also be aware of the importance of a group workspace.

Embracing company culture and developing relationships can be difficult to do digitally. Businesses should consider how they can adapt the workspace to maintain these important relationships and encourage communication, collaboration and engagement. Larger meeting spaces, for example, can provide space for company meetings, training sessions and events where the whole team can gather.

Could it work for the factory?

Some tasks, particularly in manufacturing, require workers to complete physical tasks using machinery that cannot leave the facility. The need for human workers also means that the industry is less prepared than others to embrace flexible working.

Workplace performance specialist Leesman published a survey of more than 700,000 employees worldwide about their experience working from home. Of the 52,240 surveyed from the manufacturing and engineering sectors, 53 per cent had no experience in working from home. In comparison, 52 per cent of people in other businesses had regularly worked from home or at least had some remote working experience. So, can the manufacturing industry embrace this new way of working?

Flexible technology

While a factory worker cannot complete all their tasks over a video conference service, facilities managers can invest in technology to increase flexibility. Virtual reality (VR), for example, allows teams across different areas of the business, or even different geographies, to collaborate. Manufacturers could use VR to host meetings, train new employees using a virtual machine and tools or allow multiple teams to collaborate on a project from different locations.

Wearable devices can also improve collaboration between factory workers and management staff who could work from home. For example, employers can access data from devices worn by factory staff to visualise operations from their homes and ensure that staff are productive and safe. Factory employees can also use wearables and augmented reality (AR) to immediately access real time data or information that can help them complete tasks, such as machine maintenance, accurately and quickly.

The future workplace won’t be the same for everyone — some roles still require people in factories or other facilities. However, we believe that all businesses can learn from the few months that the entire world was operating from home. Improving flexibility could be the answer to improving productivity.

Alex Darby is head of people at EU Automation

www.euautomation.com/uk/

Demand for resources is growing. According to the World Business Council for Sustainable Development (WBCSD) the world is currently on track to consume four Earths’ worth of resources by 2050. Governments across the world have warned that everyone, from homeowners to large, global manufacturers must consider how they can reduce demand for resources such as energy and raw materials to cut carbon emissions and safeguard the planet. 

Manufacturers must do more to reduce their contribution to increasing environmental issues. Introducing more sustainable processes can benefit the facility as much as the planet, as they will be able to improve efficiency and reduce costs. Some facilities might believe that this change requires an overhaul of infrastructure to swap to renewable energy sources, replace machinery and more. This approach could be time-consuming, expensive and wasteful. Instead, businesses should take the time to review their current processes and understand what short- and long-term changes they can make to produce goods using less materials, less energy and more ethical approaches.

Make it circular

Most facilities currently work following a linear model of make, use and dispose that creates a lot of waste because the product will only have one life and left-over energy or material will be wasted.

The circular model differs and encourages manufacturers to keep resources in use for as long as possible. Manufacturers should consider how they can design waste out of the production process, the goods manufactured and the everyday running of the facility.

For example, powering large facilities requires huge amounts of energy and water that can be very costly. Some of this energy will also be wasted during production. Manufacturers can look at redirecting this energy, such as wastewater, to help power the facility. Facilities that have high levels of automation can also consider reducing the lighting or heating in the facility in areas where there are no human workers to save energy.

Machinery

Sophisticated assembly lines require automation and equipment that will use a lot of energy and must be regularly maintained to run efficiently. If any of the equipment breaks down, manufacturers must make quick decisions to return to production to avoid any financial losses due to downtime.

When a machine breaks down, manufacturers can choose to repair or replace it. To extend the lifetime of the machine, reduce costs and reduce environmental impact, manufacturers should consider repairing the machine. Industrial automation parts suppliers can source the broken part if it is new, reconditioned or obsolete and deliver it to the facility quickly so it can return to production.

Investing in new technology to the system can also ensure that the facility runs as efficiently as possible. Manufacturers can retrofit smart sensors, for example, to their current system and the entire facility to gather real-time information about machine performance, energy usage and more. Analysing this data allows manufacturers to identify and optimise inefficient areas of production, reducing energy consumption and optimising productivity.

Are you sure you want to print that?

Manufacturers are introducing more automation to their assembly lines to improve productivity and efficiency. However, some manufacturers do not realise the full potential of connected devices.

By transferring internal protocols from paper to digital, mobile devices facility workers can reduce their reliance on paper, in turn reducing their carbon emissions. Going paperless can also improve logistics of everyday activity. The ability to access real-time information about inventory, orders and administration from anywhere on or off site gives manufacturers the visibility they need to improve productivity.  

Manufacturers cannot ignore the importance of reducing carbon emissions in production facilities. Investing in renewable energy and sustainable materials is important but not the only way to improve sustainability. By improving visibility of data and operations, extending equipment lifecycles and following a circular model, manufacturers can improve productivity without negatively impacting the environment.

Industrial robots have long been used to replace human workers in performing tasks that are dangerous, dirty or repetitive. These robots are often large and bulky, caged machines used to do the heavy lifting in applications such as packaging and palletising. Multiple industrial robots can be integrated for a fully automated production line, but it is important that site managers choose the right robot for the job.

Three types

There are three types of industrial robot that are commonly used to automated manufacturing processes. The first of these is the six-axis robot that has traditionally been a popular choice for manufacturers. They operate using six-axis of motion, sometimes called the six degrees of freedom, and are ideal for applications that require complex motions. Crucially, programming of these machines is easy, so operators don’t need to have advanced programming skills to use them. These robots can make use of AI software and machine learning to pick up processes and improve on them – self-coding their programmes when necessary.

Next, is the Selective Compliance Assembly Robot Arm (SCARA) family of robots that are very popular in small robotic assembly applications. SCARA robots have a solidly mounted base in a fixed position and the arm is rigid in the z-axis, offering rotational motion in the xy-axis.

Finally, there are collaborative robots, otherwise known as cobots, that have been designed to work safely alongside humans in a shared workspace. These robots, with their increased flexibility and dexterity, can complete more delicate tasks that conventional robots cannot, such as polishing fragile materials in the production process. Demand for this technology is on the rise, with the global cobot market expected to reach $9 billion by 2025.

Which to choose

Manufacturers need to consider the production speed and volume that they are looking to achieve when deciding what type of robot to adopt in their facility. Manufacturers in sectors such as bottling or packaging, that need a much higher production speed or volume, can benefit from purchasing conventional robots like the six-axis robot. The logic is simple. Fewer human operators means there is less chance to slow the system down and production will increase. Multiple industrial robots can be integrated for a fully automated production line.

Because of their flexibility, and relative ease of use compared to fully automatic robotic systems, cobots are generally considered to be an affordable and attractive choice for small and medium sized businesses. These manufacturers can benefit from the traditional value proposition of robots — namely that they can carry out repetitive or unsafe tasks, freeing up human workers to add value — but at a much lower cost of entry.

Jonathan Wilkins is director of industrial parts supplier EU Automation. For more information visit http://www.euautomation.com

It is common for manufacturers to use robots to carry out repetitive tasks, often in hostile environments. But what if these environments are also hostile to robots? Also, how do you protect an ageing workforce from the heavy physical workload, repetitive movements and non-ergonomic postures which undermine productivity? Exoskeletal technology now has an answer for this.

Consisting of a metal frame fitted with motorised muscles to the outside of your body, a wearable robot, more commonly known as an exoskeleton, can multiply its user’s strength and enable workers to carry out a variety of industrial tasks. Applications range from muscle support for rehabilitation to industrial suits, which allow you to lift heavy weights with next to no effort.

A tailored suit

The global exoskeleton market size was valued at $25.4 million in 2015 and is projected to grow at a CAGR of 58.4 per cent between 2018-2025. Apart from the obvious medical and healthcare use, demand is being driven for exoskeletons in military and industrial use too.

The prevalence of different types of stationary and mobile exoskeletons, driven by pneumatic, hydraulic and electric actuation, and powered by fuel cells, batteries, or mains power, makes it vital that manufacturers know what’s best for them. To meet the demanding needs of industrial applications, plant managers should choose exoskeletons that are lightweight, comfortable, safe as well as minimally invasive to the surrounding environment.

Plenty of options are available to manufacturers. For instance, many companies are now developing single-joint wearable robotics rather than full body powered suits which tend to be heavier and more obstructive. Upper extremity exoskeletons, such as Ottobock’s Paexo, provide support to the upper body, arms and shoulders. Meanwhile, lower extremity models provide support to the legs, hips and lower torso which is useful if tasks require heavy lifting, as shown by the rehabilitation system developed by ReWalk.

Helping your workforce

In many ways, exoskeletons are collaborative robots in their truest form. Robots and humans are not just working side-by-side, they are working as one.  Not only will this make manufacturers more productive, it will result in fewer injuries, less soreness and less exhaustion.

As well as this, plant workers will benefit from the improved skillset that will come from using an exoskeleton to complete their tasks. Since wearable robotics enable and support workers to do tasks that are otherwise dangerous for a single employee to do, such as lifting extremely heavy machinery, they can complete tasks with more confidence. If exoskeletons can help people walk again then they will certainly offer great benefits to manufacturers looking to optimise the efficiency and capability of their workforce.