How Will Brexit Affect Manufactuers in the UK?

The debate around Brexit continues to intensify as not only the UK, but also our trading partners across the world, patiently await definitive announcements regarding our exit from the EU. The big question on the lips of all manufacturers is how will Brexit affect manufacturers in the UK?

At Granta Automation we remain cautiously optimistic about its effect on the sector and the economy as a whole and below we look into the current state of manufacturing and how things might develop over the next 12 to 18 months.

 

A positive end to 2017

Manufacturing in the UK experienced an unexpected upturn throughout most of 2017, ending on a largely positive note, with the average between October and December 2017 the highest seen in the industry for almost ten years. However, there is still an air of uncertainty surrounding the long term effects of Brexit and how it will directly impact on the manufacturing sector.

As it currently stands, manufacturing makes up approximately 10% of the UK economy although this doesn’t take into account the many trades and jobs that support – and are supported by – the industry. How Brexit will impact on these industries is unknown and the ripple effect created through these associated industries could prove problematic.

 

British goods retain their value

Although 2017 ended on a high note, the economy has slowed down somewhat at the start of 2018. The first quarter saw growth drop to 0.4%, an 8 month low that is in stark contrast to the rise in production seen the previous year. Since the Brexit results were announced in June 2016 it is the second lowest reading, despite output remaining above 50 on the purchasing manager’s index.

With the pound starting to regain its strength British products are more expensive compared to previous years. Although, a new report by Barclays in February highlighted that overseas consumers were willing to pay up to 22% more for British food goods. This also translates across to other industries such as automotive (10%), alcohol (9%) and clothes (9%) with consumers prepared to pay premium prices for products that are labelled as British made.

 

Areas of concern

Not every study offers such good news, however. Based on the current models of Brexit currently under consideration by the government there are concerns that British manufacturing exports could be reduced by a third, as detailed by the UK Trade Policy Observatory in their paper released earlier this year.

 

Their analysis was based on leaked estimates from the Treasury, building a more comprehensive model to assess the impact on 122 manufacturing sectors. They suggest that areas such as Sunderland, Coventry, Derby and Birmingham could be amongst those worst affected by the current Brexit plans. Taking into account increases to other domestic industries their final estimation was a total reduction in manufacturing output of 3.6%, with carmakers facing the biggest uphill struggle. The aerospace and pharmaceutical manufacturing sectors were also singled out as being particularly hard hit.

 

2018 and onwards

The collapse of Carillion at the start of the year may have put many other firms on edge about the coming 12-24 months, however, it should not be forgotten that the problems the construction giant struggled to overcome were far more complicated than simply being related to Brexit. It should also be remembered that optimism in the manufacturing sector was high at the start of the year, as illustrated by manufacturers organisation, EEF’s report which saw many business anticipating more productivity in 2018.

Industry 4.0, or smart manufacturing as it is also known, also holds significant opportunities for manufacturing companies, along with increased investment in automation and robotics and further integration of Internet of Things (IoT).

Of course, the analysis so far is based on hypothetical studies and research, using concepts and plans that are far from set in stone. Every week seems to bring a new development as disagreements continue between the Houses of Parliament, the House of Lords, the Irish government and the European Union themselves.

The uncertainty is unsettling to the business community as a whole and isn’t exclusive to the manufacturing sector, but until discussions are complete, decisions are made and new policies implemented, there is no sure fire way of knowing how the economy will be effected in the long run. The good news is that despite the lack of clarity the manufacturing sector continues to evolve and move forward and there are still a lot of exciting developments we can all look forward to over the coming months.

 

To find out how we can help you keep pace with the changing face of manufacturing in the UK, contact our automation consultants who are always on hand to quickly respond to your questions, and provide detailed answers based on your current automated palletising  requirements. They can be contacted on 01223 499488, or via email at helpline@granta-automation.co.uk

 

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Robotic Palletising Cell Case Study – Granta Automation

Brief

Granta were asked by a medium sized food factory to look at ways of improving their current manual bag stacking process.  They were packing dry, free-flowing, granular product into 25kg bags and then manually stacking the filled bags onto pallets at the end of the production line.

They had been having complaints from staff in relation to back pain due to lifting and stacking the 25kg bags all day. There were also other issues with manually stacking the bags onto pallets:

  • Stacking quality was poor
  • Other health and safety and RSI issues
  • Manual labour was not fast enough to keep up with production speeds and was therefore reducing the machine’s output capacity.

With the need to increase production speeds and address the health and safety issues they were experiencing, they requested Granta to come up with a solution.

The Solution

We carried out an on-site assessment of the existing process so that we fully understood the customer’s requirements.  During this assessment we realised that there was an added challenge to automating the palletising process: once the bag had been laid down after the mouth of the bag had been stitched, we would then need to redistribute the product within the bag, prior to stacking it on the pallet.  We knew that flat bags were going to play a key part in achieving a neatly and safely stacked pallet.

Following our site visit, our automation consultants held a brainstorming session to come up with the best automation solution for this company.  We explored ideas and methods and discussed these with our customer and collaboratively came up with the following solution.

We designed, built and installed a bespoke robotic palletising cell for the end of their production line which included:

  • Bag flattening conveyors installed after the existing bag stitchers to redistribute the product in the bag.
  • A robotic palletiser with a specialist bag gripper; designed to cope with the floppy nature of the bags.
  • Specialist 3D safety scanner to protect the robot working area. A 3D safety scanner was installed because space was limited and an unusual layout was required to allow forklift access to the pallets.
  • The ability to allow for different bag fill weights and product characteristics by adjusting the layer height on the pallet.

The solution proved to be very successful and gave the food company an increased production throughput of 150%!

The Sequel

With the installed automation having been so successful the customer asked us to replicate the same system on two more of their manual bagging lines. Our automation consultants reviewed the palletiser system we had installed and came up with a scheme of using one robot to serve the additional two lines rather than having to install two separate robots.  This would save the customer cost and space.

Following consultation with the customer, we designed, built and installed the following system;

  • Two bag flattening conveyors – one on each of the two lines after the existing bag stitchers.
  • A KUKA robot with a specialist bag gripper that is able to stack to four pallet stations. The robot has the ability to stack the output from either line to any of the four stations; giving great flexibility to optimise the robot output to match the individual lines output.
  • Fencing and guarding around the four pallet station stacking area and robot.
  • A gate system with safe zone interlock to allow removal of two pallets while the palletiser continues stacking on the other two pallet stations.

The Final Outcome?

A very happy customer that has increased their production throughput significantly and improved health and safety in their workplace by reducing the risk of repetitive strain injuries.

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Key Trends In The Manufacturing Industry – What You Need To Focus On For Your Manufacturing Plant in 2018-2019

The success of the manufacturing sector relies on constant evolution of the processes involved, utilising new equipment, technology and techniques to find optimal efficiency gains. The exponential growth of technology, in particular, remains as true today as it did 50 years ago and the production landscape is changing shape faster than ever before.

Keeping pace with developments allows your business to remain a constant and relevant force in the market place. With that in mind, we’ve listed what we believe to be the key trends in the manufacturing industry and what you need to focus on for your manufacturing plant in 2018/19.

 

The Internet of Things (IoT)

The need to increase efficiency, reduce costs, improve safety and incentivise product innovation are just some of the challenges facing manufacturers who are considering implementing the Internet of Things into their operations.

IoT enabled equipment will allow manufacturers to maximise the lifespan of their technology without disturbing the output. With lower levels of maintenance planning, equipment downtime and maintenance costs, it provides a number of essential advantages in an increasingly competitive market.

Enhanced connectivity will dramatically change how manufacturers capture and use key data. In turn this will provide stronger insights into the supply chain and inventory processes. Optimising production in real-time will enable businesses to become more efficient and limit wastage output.

 

Industry 4.0

Otherwise known as smart manufacturing, Industry 4.0 has been labelled as the 4th industrial revolution. The use of advanced manufacturing technology right across the production chain provides vast improvements on processes, enhancing efficiency and making the factory floor safer for employees. The ability to monitor and analyse assets more closely ensures it is possible to constantly tweak and evolve the level of output.

The implementation of Industry 4.0 provides a number of advantages for manufacturers, including increased productivity, faster reaction times to customers, the creation of new services and product lines, as well as improved delivery to market. With the right framework in place and the critical business areas addressed, smart manufacturing opens up extensive and exciting new possibilities across almost every sector.

 

Cobot Manufacturing

Collaborative robots are already in place in a number of factories in a wide number of industries. However, technology never stands still and the evolution of these robots means lightweight and agile versions are set to become more common place in the manufacturing sector.

Cobots are being designed to be more sensitive to respond to human interaction and reduce the level of risk involved in working more closely together. For example, built in sensors can detect the presence of a human and reduce the operating speed the closer the human gets to the machine. Cobot’s can also control the speed and force being applied and instantly stop when an obstacle is encountered, significantly lowering the impact density.

 

Augmented reality

While virtual reality has made great strides in the past decade, experts have always felt that augmented reality offered even greater opportunities. The blending together of the real world with advanced computer generated visual aids may still be in its early stages but interest from the manufacturing sector is rapidly gaining pace.

For example, the use of wearable technologies connects workers to a goldmine of information and data to help optimise job performance while increasing safety. AR could be implemented on assembly lines, skilled training, maintenance, support services, quality assurance and automation.

At one time this sort of technology may have seemed light years away from being used in real time environments. This is no longer the case with AR actually in use in a number of facilities right now. As the technology improves exponentially, so will the myriad of ways it will improve the manufacturing sector.

 

Additive manufacturing

The use of 3D printing technology is becoming more common place, helping to introduce efficient and cost effective practices. Additive manufacturing allows for the prototyping, tooling – and on occasion – the production of applications used within the manufacturing process.

3D printing enables manufacturers to reduce the large inventories of spare parts required to respond quickly to customer orders. By being able to produce the part without large stock levels adding to their storage space costs, response times are maintained, while being more cost effective and maintaining the integrity of the equipment supplied.

Using additive manufacturing processes to create prototypes and tooling moulds increases operational efficiency while also lowering costs. Rather than running up huge costs and taking months to produce, 3D printing enables this to be produced within a matter of days.

 

To find out how we can help you keep pace with the latest automated palletising solutions for your facility, contact our automation consultants who are always on hand to quickly respond to your questions, and provide detailed answers based on your current requirements. They can be contacted on 01223 499488, or via email at helpline@granta-automation.co.uk .

 

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Manufacturing Industry Statistics for 2017 and Anticipated Statistics for 2018

Manufacturing-statistics

With the end of the financial year upon us, we take a look back at 2017 in the manufacturing sector to review how it has impacted companies in the UK. The last 12 months have largely been a success for many in the industry which has led to a number of bullish predictions for 2018 and beyond. Manufacturing accounts for approximately 10% of the British economy and usually provides a strong indication of what the coming months hold in store in financial terms for the country as a whole.

Take a look at the manufacturing industry statistics for 2017 and some of the anticipated statistics for 2018 below.

 

Statistics for 2017

The strength of the economy came as a surprise to many at the tailed end of 2017, which subsequently led to a more optimistic outlook for 2018.

The National Institute of Economic and Social Research revealed the UK GDP grew by 0.6% in the final three months of last year, up against a predicted forecast of 0.5%. Taking this new estimate into account the UK economy as a whole expanded in 2017 by a total of 1.8%.

The good news is that the manufacturing sector played a significant role in this unexpected rise. In November 2017 alone, the industry grew by 0.4%. More pleasingly, the average between October to December was the highest seen for almost a decade, while also being 3.9% higher than in the same period in 2016. Seven consecutive months of growth marked the first time in 20 years the sector had experienced such a boom.

A growth in exports is the driving factor behind this current surge, assisted by a weaker pound and growing demand from economies in the Eurozone. According to a survey conducted by the Confederation of British Industry (CBI), 42% of those questioned stated output had increased in the final quarter of 2017, with only 11% stating it was down. 28% said their total order books were busier than normal, while 11% revealed orders had slowed in the same period.

 

What 2018 holds in store

The growth experienced in 2017 has created an optimistic mood for the next 12 months. In particular, manufacturers that have already committed to or are planning to, embrace the advantages that technology can add to their business, look set to benefit the most. This includes tools such robotics, automation, cognitive computing/artificial intelligence (AI), big data and analytics, and internet of things (IoT).

PricewaterhouseCoopers’ (PWC) Annual Manufacturing Report highlighted the important role Industry 4.0 (automation and data exchange) will play in the coming years. 80% of those included in the report believe digital technology has been beneficial to their business, while a further 79% agreed it will allow them to widen their customer base through service-based offering.

A survey of 378 firms in January by manufacturers organisation, EEF, showed that manufacturers are expecting the current cycle of growth to continue. Many are anticipating larger productivity gains for 2018, with 66% of the company’s surveyed anticipating improvements in efficiency.

The EEF also estimate the sector will continue to expand by approximately 2% in 2018, which is faster than the rate at which they expect the UK economy to grow as a whole. This is tempered slightly by output dropping to its lowest level in eight months in February this year, although the demand for new orders indicates this will not be a continuing trend for the next 12 months.

While the uncertainty that continues to linger around Brexit is weakening the strength of the pound, the positive effect it is having on manufacturing looks set to continue in the short to medium term at least. Coupled with the steady improvement of the global economy, this also means demand from overseas should remain stable.

This isn’t to say that Brexit is not a huge concern for industrialists. A lack of a clear national economic purpose from the government means that while many companies are keen to invest in new technology, some remain hesitant in the current climate. With the EU’s Michel Barnier highlighting the need to have the Brexit agreements in place by October of this year, it highlights how important the remainder of this year is to the manufacturing sector.

 

Conclusion

As we can see, after steady growth across most of 2017, there is currently a lot of optimism in the industry. At the same time, businesses remain cautious as they are aware how quickly the market could change due to the unknown outcome of the Brexit negotiations. With the global economy expanding by 3.3% in 2017, and the World Bank predicting an expansion of 3.1% in 2018, the export market looks set to continue bearing fruit for British manufacturers.

 

To find out more detail on how we can help your business in 2018, email our helpline helpline@granta-automation.co.uk, or call us on 01223 499488.

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How Can I Improve The Throughput Capacity Of My Machinery?

Improve-throughput-capacityMaintaining an efficient throughput is essential to the success of any manufacturing facility. In order to remain competitive production must be sustained at a certain level to keep a steady flow of goods heading out to customers. Any break or delay within the factory can have a negative effect on the rest of the supply chain, creating delays and complications with clients who might begin to shop around for a better service.

Quickly identifying issues within the production cycle that may be preventing the system from maximising throughput will create an efficient manufacturing process and reduce the possibility of customer complaints. As a brief overview, we are going to cover a number of ways in which you can improve the throughput capacity of your machinery.

 

Clear the bottleneck

In many cases the easiest way to improve throughput capacity is by analysing, identifying and clearing bottlenecks in the process. Bottlenecks occur when a particular part of the system slows down or underperforms, and effects the speed of the process as a whole. Not all bottlenecks are easy to identify so it may take some time to carefully go through each stage to find where the problem exists. Visit our blog post ‘How do I Identify a Bottleneck in My Production Process?’ for help with identifying bottlenecks.

Solutions may include adding additional elements to enable more parts to be manufactured. The opposite could also be true; a section or station may need to be removed and be replaced with something that is able to deal with demands placed upon it. Not everything will come down to the actual machinery itself as you will need to strike the right balance between the time, space and cost involved in implementing the solution.

 

Keep staff trained and motivated

A good factory or manufacturing facility is only ever as good as its staff. That is also true of highly automated operations as the human factor still plays a vital role in its success.

The ongoing training of staff is not only an investment in their skills but a way to improve the quality of work within the organisation. The direct link between this and efficiency on the production line is unmistakable as undertrained employees will not have a full understanding of where improvements can be gained. When staff are engaged with their work and the process as a whole they see how their role impacts the bigger picture. If they are given guidance on how to use the machines and maximise their section of the process, time can be saved and throughput increased.

 

Implement automated machinery

If a strong business case can be made to purchase and install automated machinery then the improvements made to the throughput will be almost instant. Whether you operate a manual facility or use a semi-automated process, the introduction of automation will always have a positive impact on quality, speed and efficiency.

E-retailers in particular are transforming the make-up of their warehouses to accommodate the fast paced demands required of them. With short deadlines required from the point of order through to the delivery of the product, automated machinery is able to retain quality of service at a much faster rate.

Those in the manufacturing sector are also realising the benefits of automation; improved quality, increased accuracy, instant fault reporting, reduced downtime, and improved traceability are just a few of the many benefits.  Some of the machines that provide great benefit to the manufacturing sector include robotic machine tending and assembly systems and production monitoring and data logging systems and automated palletising solutions. An assembly system significantly improves loading and unloading times, while a monitoring system maximises efficiency by producing detailed reporting on the system during operation allowing you to track downtime and eliminate any unnecessary downtime.  Automated palletising systems allow your manufacturing process to keep running during break times, and reduce the risk of RSI.

 

Improved quality control

Upon analysis you may come to the realisation that the speed of the production line is not where the problem lies. No matter how quickly your assembly process may be, if the quality of the product is not up to standard you will be facing a higher rejection rate.

The impact created from so much time and money being wasted on poorly made products will soon begin to show on the balance sheet. This will no doubt also have a knock-on effect to the deliveries and keeping up with demand for the product.

These consequences are felt some time after the initial problem begins and there are ways to be more efficient by improving quality control and increasing throughput. Vision inspection systems provide accurate quality assurance to ensure productivity remains high, with less money, time and resources wasted on poorly manufactured products.

 

Improved use of machinery

Reviewing the process within any facility should be common practice implemented even when the system appears to be running smoothly. Getting the most of your process, whether led by machines or by other means of operation, will create an ambitious culture of maximising the tools at your disposal.

If automated machinery is already running within the facility throughput can still be improved by thinking of ways in which the machines can work together. Rather than using individual machines to complete specific tasks, and creating wasted product movement, there are ways in which custom automation can unify the processes. Even in operations that rely on older machinery, these can still be adapted to work with new technology. The time lost by waiting for the transfer from one machine to another can be reduced, improving efficiency and ultimately generating a higher throughput.

 

Conclusion

There is no one-size-fits-all solution to improve your manufacturing throughput. Whether you are experiencing issues that are slowing down production, or looking at ways to become more efficient, the suggestions above will give you a strong starting point to begin your analysis.

If you are looking to introduce automated palletising within your business, you can contact one of our automation consultants who will be happy to talk through the options available to you. Simply email our helpline helpline@granta-automation.co.uk, or call us on 01223 499488.

 

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What Are The Different Types of Pick and Place Robots?

Robotic-pick-and-placepick-and-place

Pick and place robots are available for a wide range of applications.  Whilst this gives you an overview of pick and place robots, the exact type of pick and place robot to suit your application will be very dependent on your specific requirements.

Robotic pick and place systems can be configured for multiple different types of products and plant layouts. As a robotic handling system, it can run without any operator input, to pick and place parts from one process into another, or from a process into packaging or any other application where items need to be moved from one place to another. A robotic pick and place system will reduce repetitive strain injury and worker fatigue, whilst increasing production throughput, productivity and efficiency.

Robotic Arm
Probably the most common type of pick and place robot is the robotic arm type; which typically come as 5 axis robots for standard pick and place application in plane, or 6 axis robots for more complex applications where the products needs twisting from the horizontal (similar to the image above).

Cartesian
The cartesian robot is also a very common type of pick and place robot, that used to be cheaper, but is now not so commonly installed apart from for injection moulding machines.

Delta
Delta robots are mounted above conveyors and are typically used for high speed pick and place applications.

Fast Pick
Fast pick robots are also another option for fast pick and place applications; with cycle times as fast as 150 cycles per minute.

Collaborative
In recent years a wide range of different types of collaborative robots have hit the market and these are becoming increasingly used in industrial applications, but they are mostly smaller, slower robots with less of the complex functionality available. This limits their usefulness for some applications.

 

Installing and commissioning robotic systems requires a wide range of skilled automation engineers; from robot programmers and PLC programmers through to mechanical engineers and CAD design engineers.

A robotic pick and place systems would usually include the following:

  • A robot.
  • Touch screen control system – giving you set up options and a lot of surplus capacity for adding extra functionality such as, conveyors, link up with other machinery and remote production logging and monitoring.
  • Guarding and doors with interlocks and safety as required.
  • Bespoke robot gripper (the price may vary depending on how complex your items are to pick up and handle).
  • A basic conveyor.

With a bespoke designed pick and place system you will also be able to have the design modified suit your requirements. Modification can include; layout, guarding, how many products the robot picks up at once, stacking configuration and much more.

 

Small Robotic Pick and Place System

Small robotic pick and place systems are usually used where the product is small, and the distance that the product needs to be moved is short. Some example applications where a small pick and place system would be appropriate include; packing chocolates into boxes, transferring small items from a conveyor to a tray or conveyor, placing components into a circuit board, and orientation of small parts.

 

Medium Robotic Pick and Place System

Medium pick and place robots are usually used where the product is larger and needs to be moved over a longer distance, or where there are multiple smaller pick and place applications that come together.  Some example applications of a medium pick and place system include; moving products between machines, movement of products within a food production process, and assembly of components.

 

Large Robotic Pick and Place System

Large robotic pick and place systems are usually used where the product is very large, or very heavy for example products weighing 100Kg or even up to as much as 1,000Kg +.  Some example applications for a large pick and place system include; moving cars on a production line, moving large sheets of glass and raw materials on production lines etc.

 

Conclusion

Whilst this post gives you a broad overview of the different types of robotic pick and place systems, it is always important to have your own requirements professionally assessed to ensure you receive the optimum solution to meet your needs.  Along with many other benefits, a truly bespoke pick and place system will enable you to increase efficiency, reduce product defects, improve productivity, reduce wasted space, reduce the risk of repetitive strain injury, run your plant 24/7, and improve profits.

If you would like to discuss which robotic palletising pick and place system is likely to be best suited to your application then contact our automation consultants on 01223 499488, or helpline@granta-automation.co.uk .

 

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Advantages and Disadvantages of Robotic Automation

dreamstime_30704532

The growing popularity of robotic automation across a wide range of sectors looks set to continue over the next few years, as businesses look to take advantage of the many benefits it offers. Manufacturers in the UK are starting to invest more in the technology in preparation for our departure from the EU, allowing them to maintain their competitive edge in the market.

Naturally, not everyone has been convinced of the advantages robotic automation can deliver. There is still some cautiousness about adapting an existing production line, with some reasonable objections posed by those yet to try the technology. To address both sides of the discussion, we have put together a few brief advantages and disadvantages of using robotic automation.

 

ADVANTAGES

Cost Effectiveness

There will be no lunchbreaks, holidays, sick leave or shift time allocated for robotic automation. It can be set to work on a repetitive cycle, and as long as it is maintained correctly, it will continue to do so until programmed otherwise.  This eliminates the risk of RSI occurring.

The increase in production at a lower cost produces obvious benefits for any manufacturer. The cost of investment can be recovered in a relatively short space of time and the gains from that point onwards are exponential to say the least.

 

Improved Quality Assurance

Few workers enjoy doing repetitive tasks and after a certain period of time concentration levels will naturally decline. This lapse in concentration is known as vigilance decrement and can often lead to costly errors for the business and sometimes serious injury to the member of staff.

Robotic automation eliminates these risks by accurately producing and checking items meet the required standard without fail. With more product going out the door manufactured to a higher standard, this creates a number of new business possibilities for companies to expand upon.

 

Increased Productivity

Using robotic automation to tackle repetitive tasks makes complete sense. Robots are designed to make repetitive movements. Humans, also by design, are not. The introduction of automation into your manufacturing process has many different productivity benefits, some of which are shown here.

Giving staff members the opportunity to expand on their skills and work in other areas will create a better environment which the business as a whole will benefit from. With higher energy levels and more focus put into their work, the product can only improve, which will also lead to extremely satisfied clients.

There are several different calculators available for calculating the productivity of your processes which are available to download from the resources section of our website.

 

Work In Hazardous Environments

Aside from potential injuries in the workplace, staff members in particular industries can be asked to work in unstable or dangerous environments. For example, if a high level of chemicals are present, robotic automation offers the ideal solution, as it will continue to work without harm.

Production areas that require extremely high or low temperatures typically have a high turnover of staff due to the nature of the work. Automated robots can minimise material waste and remove the need for humans to put themselves at unnecessary risk.

 

 

DISADVANTAGES

Potential Job Losses

One of the biggest concerns surrounding the introduction of robotic automation is the impact of jobs for workers. If a robot can perform at a faster, more consistent rate, then the fear is that humans may not be needed at all. While these worries are understandable, they are not really accurate.

The same was said during the early years of the industrial revolution, and as history has showed us, humans continued to play an essential role. Amazon are a great example of this. The employment rate has grown rapidly during a period where they have gone from using around 1,000 robots to over 45,000.

 

Initial Investment Costs

This is typically the biggest obstacle that will decide whether or not a company will invest in robotic automation, or wait until a later stage. A comprehensive business case must be built when considering the implementation of this technology. The returns can be substantial and quite often occur within a short space of time. However, the cash flow must be sustainable in the meantime and the stability of the company is by no means worth the risk if the returns are only marginal. Yet, in most instances there will be a repayment schedule available, which makes it a lot easier to afford and control finances. Our downloadable automation payback calculator also has a finance scheme option so you can see how this would work for you.

Increased throughput and reduction in defects both need to be considered along with the capital expenditure when deciding whether or not there is a business case for investment. Intangible benefits also need to be considered, and we have created an intangible benefits downloadable calculator to help you with this.

 

Hiring Skilled Staff

Over the past decade manufacturers have found it harder to source skilled staff members to fill the specialised roles in their factories. The introduction of automation adds another layer to that conundrum as the robots require programming and a knowledge of how to operate them. In reality, this opens up further opportunities for existing employees to be trained and expand their own skill set. An automation company can assist with the initial installation and set-up process, and with the right expertise, staff can learn and adapt to manage the robots in the long-term.

 

To find out if robotic palletising offers the right solutions for your business, try our Project Builder which will guide you through the process of understanding the different options available, along with potential costs. Alternatively, you can always contact our sales team who are always on hand to quickly respond to your questions, and provide detailed answers based on your current requirements. They can be contacted on 01223 499488, or via email at helpline@granta-automation.co.uk

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Why does Automation Enable a Factory to Reduce Production Costs?

cut-costs

In today’s increasingly competitive marketplace automation has to be viewed as a long term strategy worth investing in. Some companies can baulk at the initial, or staggered, costs involved in moving from manual processes into automated procedures.

Yet to do so would miss the point and one of the main benefits that automation offers. The key to evolving into automated manufacturing is found in the short-to-long-term cost cutting it produces. Simply put this means the longer automation is used within production, the more powerful its ability to reduce costs becomes. Not only will it lower manufacturing overheads but increase output at the same time, a fact that many businesses are looking to take advantage of. But how is that possible and why does automation enable a factory to reduce production costs?

Improved Accuracy

While the long-term financial returns on automating particular processes will continue to increase, there are many quick ROI’s to be found too. Products can immediately be manufactured with the exact same specifications, with far lower tolerances, creating a far more consistent product.

Part cycle time also decreases and will naturally create a more efficient production line. Automated machines or robots have no need to take breaks like regular staff, therefore working at a faster rate and manufacturing more products within the same space of time. This extends further into the size of the machines which will create a smaller footprint than manual processes, allowing cubic space to be utilised more effectively.

 

Working With Humans

Automated technology continues to improve year-on-year and as such, so does its ability to work collaboratively with the human workforce. Sensor systems have become far more adept and built with safety in mind, and features such as collaborative robots that can detect too much resistance to their movement so they automatically shut down. The positive effect here is a safer workplace for employees, and a far lower risk of accidents occurring which can lead to costly lay-offs or even compensation claims.

Enhanced Data Capture

The data captured during manufacturing provides not only an invaluable insight into improving best practices but also to maximise efficiency and control over machine usage. Precise detail about wastage, energy consumption and Overall Equipment Effectiveness (OEE) can be analysed and used to constantly improve the production process.

Over time this will build a pattern of data that will produce predictive capabilities for factories to understand where and when machines may break down, minimise wastage and significantly lower energy costs. Rather than averaging these elements out across multiples lines produced within the same facility, the exact data for each product can be captured and analysed. This will allow companies to pinpoint definitive costs for every line produced in their factories.

Lower Labour Costs

As is the case in many specialised trades, manufacturers are finding it increasingly difficult to recruit skilled workers. A generation or two ago the sector was seen as offering a stable career, but with school leavers given access to an increasing range of educational courses, many young people are opting for office-based roles.

In order to keep pace with growing consumer demand, the skill gap can be filled with the use of bespoke automation. One machine can perform the tasks of several workers and with none of the typical staff benefits required, the cost remains sustainably low and can therefore be projected over a longer period of time.

 

Efficient Production Lines

If a strong enough business case cannot be made to invest in automated machinery that can take on several duties, there are still alternatives available. A production line can operate more efficiently if existing machines are linked together through the installation of automated processes. This can be applied to older machines that can be retrofitted with new technology or connected via robots and conveyer systems.

The transfer time between machines will be shortened, creating faster throughput and overall improved manufacturing efficiency. Labour costs will also be reduced, and the overall unit cost per item will become cheaper, increasing profits and opening new investment opportunities.

Bespoke Automation

Specialised machines built to perform specific tasks have always existed in one form or another. While they offer many advantages, one of the biggest draw backs is how isolated they become from the overall manufacturing process. Automated machines that are designed to perform bespoke duties can not only do so at a faster rate, but can, if required, take on additional processes.

Alternatively, it is much easier to program an automated machine to work in conjunction with other areas of the production line. This gives you all the advantages of utilising a bespoke system without the concerns of slowing down manufacturing throughput.

Conclusion

Lowering costs is one of the main advantages of automation investment, a factor that a growing number of factories are taking into consideration across the globe. Automation provides the answers to a number of manufacturing issues, while delivering tangible results on the bottom line. Delivering the best possible experience for your customers starts in production and this exciting technology allows you to find that all important competitive edge.

If you would like to find out how automated palletising systems could help you reduce your production costs, contact us on 01223 499488 or helpline@granta-automation.co.uk and we will be very happy to discuss this with you.

Alternatively, download our Automation Project Payback Calculator to find out what your cost savings would be after automating your processes.

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How does Automation Affect Productivity?

Improved productivity is the golden ticket that every business hopes to win!

golden-ticketIf this can be achieved while also reducing costs then this perfect combination will only lead to improvements across the business as a whole. The main purpose of automation is to meet these two crucial factors which is why the use of technology is becoming so common place right across the supply chain. Productivity is crucial to gaining a sustainable advantage over competitors and increasing a foothold in the market. Meeting those targets is an analysis that needs constant attention, and the implementation of the smallest of changes can have a hugely beneficial effect. We’ve listed a small number of productivity benefits that can be gained from the introduction of automation into your manufacturing process.

 

Less Manual Delays

With less interruptions in production flow, the benefits here are easy to understand. Manual quality assurance checks are no longer required if an automated equivalent is installed, increasing the hourly throughput. This also applies to faults that occur during manual production processes. Human error results in the loss of significant response time when assessing and repairing the problem. In-built technology within an automated system such as vision inspection can perform on-going checks and balances, and if production is forced to halt, the downtime is far shorter.

 

Optimal Machine Efficiency  

Rather than spread elements of the production process across multiple machines or devices, automation allows one machine to perform an array of different tasks. Without the need to transfer product parts from one machine to another and with more accuracy gained, a larger number of units can be produced within the same period. Bespoke automation allows each machine to be designed and built to match the specific demands of the manufacturing process it is being installed into.

 

Manual Productivity

Not every part of the business can be automated and the growing fear over its impact on job stability is one of the main concerns in the workforce. However, increased use of automation does not have to result in a reduction of the human work force. Rather than placing staff on boring, repetitive tasks – which often leads to injuries and interruptions in production – re-positioning them onto jobs that utilise their skills will enhance their experience and improve productivity in other areas of the business. Improving productivity does not just mean directly within production, but also how this naturally filters through and impacts other connected areas of the business.

 

Manufacturing Data

Valuable information about the production process can be retained through the use of automation ensuring that knowledge typically lost during a manual process is instead stored for analysis. This is essential to further improving the use of the automated machines that are currently in use. Data logging systems allow this to be shared across the business, especially within the early design stage. The connection between these two business functions allows product designers to understand where changes can be made to find extra productivity in production once the product is ready to be made.

 

Management and Supervision

Similar to how workers can be moved away from repetitive tasks into areas that reflect and encourage skill development, there is a positive effect felt with the management staff. Rather than spending more time micro-managing, automation allows managers to be more creative with their resources. Of course, they will always be available to step in where required, but with more concentration focused in other areas of the business, they too can utilise their experience and skill more wisely. Management are typically in possession of years of experience, and being able to implement this within the company on a more widespread basis will only prove to be hugely beneficial.

 

Introducing New Products

The introduction of a new line of products opens the door to increased commercial possibilities but also creates new manufacturing problems to be solved. More often than not, new items are combined with existing products on the same line. Using traditional manufacturing methods this naturally slows down production due to increased changeover time, lowering the overall effectiveness of the machine. Automation, through the use of integrated robotics, can provide the ideal solution. Improved end-of-arm tooling can help maintain and improve the speed of production that existed before the implementation of the new products.

 

Conclusion

This is only a brief insight into how productivity can be improved through the addition of automation. Improved efficiency and significant cost savings will also be felt once the technology has integrated fully into the operational set-up. From production, to employees and ultimately the consumer, automation encourages a far more productive manufacturing process when compared to manual production lines.

Every manufacturing and production facility faces individual challenges that are unique to their business and market. We have worked with companies of all sizes to find sustainable solutions that can be implemented in real-time.

If you are looking for ways to increase productivity within your business, you can contact one of our sales team who can talk through the robotic palletising systems available available to you. Simply email our helpline helpline@granta-automation.co.uk, or call us on 01223 499488.

Why not use our productivity calculators to calculate the productivity of your production process and see where productivity could be improved? 2 Ways to Measure the Productivity, Effectiveness or Efficiency of your Machinery or Factory

 

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Why is the UK Government so Interested in Automation?

Why-is-the-government-so-interested-in-automation

As Brexit talks slowly edge towards deeper and more complex negotiations, the process has highlighted a range of issues across a number of industries that may otherwise have remained untouched. Production investment in the UK has been an ongoing cause for concern as lack of improvement in post war productivity becomes more highlighted than ever. Industry planning outside of the EU will require considerable organisation and investment and automation will remain central in the new manufacturing landscape.

 

The current status in the UK

Five years ago the UK, which at the time was the 7th largest economy in the world, held a worldwide ranking of 19th in terms of robot density within the manufacturing sector. According to a report by the Centre for Economics and Business Research, in 2015 the UK were behind countries such as the US, Germany, Japan and South Korea. For every 10,000 employees working in general industry, in the UK there were only 33 robots in use. In addition to this, there were only 10 robots per million hours worked. When you compare this to 133 for Germany, 167 for Japan and 131 in the US, we can see there is still some work to do.

Automation is a key global industry that will prove pivotal to the sustained growth of future economies, and these figures suggest the UK has some ground to recover. The restructuring of the manufacturing sector that occurred throughout the 70s and 80s meant that many began to see the industry as outdated and secondary to the importance of the newly deregulated financial institutions and markets. In the decade between 2005 and 2015, it is worth noting that productivity in the manufacturing sector grew three times faster than the entire UK economy. The sector is currently responsible for 45% of all UK exports which see us positioned as the 9th largest industrial nation in the world. With technology becoming more accessible and cost effective, the fourth industrial revolution is moving at a rapid pace, and the Government is keen to see the UK working on the cusp of these developments.

 

The government’s plans

At the start of this year, the government unveiled its Industrial Strategy. This outlined a plan to invest £2 billion per year by 2020 for new research and development in the tech sector. Only last week Prime Minister Theresa May announced additional funding of £17.3 million for research and development into AI in universities. These ambitious plans aim to place the UK at the centre of the next tech-driven industrial age, in an attempt to recover the shortcomings that have occurred over the past few decades.

Smart manufacturing and the Industrial Internet of Things (IIot) will build upon the work that automation has already forged over the past decade and a half. By focusing on the possibilities that automation allows, it presents the opportunity to push the boundaries of technological innovation so vital to growing the UK economy in a post-Brexit world. Robotics and integrated automation is set to revolutionise the entire supply chain. For example, when you consider that approximately 80% of warehouses still rely on manual processes, you can see the environment is ripe for development.

 

What the future holds in store

With augmented and virtual reality technology becoming far more accessible, the next generation of automated tools will provide a more interconnected landscape. This will find use in areas such as plant maintenance, predictive maintenance, virtual reality tools and processes and, of course, the continued implantation of robotics using this technology along with advanced AI.

Now is the ideal time for government and businesses to build a coherent strategy that will position the UK as a leader in the field of technological innovation. Both are aware that manufacturing will remain at the forefront of these changes and blueprints for regulatory reforms, as well as skills training, will need to be identified and clearly structured.

The good news is that many companies are planning to solidly invest in automation over the next two years. The annual EEF/Santander Annual Investment Monitor survey surveyed 328 businesses in August and over 51% stated they intended to increase their spend in this area. What the results also reveal is that this is mostly to satisfy current demand and capacity, rather than to improve productivity and increase production. Understandably, many companies are in a state of flux due to the uncertainty produced by our planned exit from the EU. This makes the need for an industrial strategy to be delivered by the government more urgent than ever.

 

 

As a market leader in automation, Granta will be a key player in the changing face of manufacturing over the next few years and beyond. For manufacturers uncertain of what Brexit holds in store, the opportunities that automation offers right now can add significant benefits to your business, providing a crucial competitive edge.

Our sales team are also able to answer any further questions you might have and they can be reached on 01223 499488 or by email helpline@granta-automation.co.uk.

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