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Manufacturing is increasingly vital to increasingly competitive global markets 27 Sept 2010, www.eama.info) shows
the UK economy. It already and grow exports into the rapidly that UK companies, despite being
contributes £140 billion and is developing economies of the world. innovators in product and process
responsible for over half of the technology, are falling significantly
When applied appropriately the
country’s exports. behind their European competitors
benefits are clear. Automation of the
in adopting automation.
The growth of the UK’s manufacturing manufacturing process not only drives
base, based on sustainable businesses, costs down, it improves quality, reduces Many UK SMEs think automation is
is key to rebalancing the economy waste and optimises energy use. only for big companies.
and generating future prosperity It does not have to mean fewer jobs.
What they may not realise is that it
for the country. However the results of a study we have
is being used, increasingly, by their
just carried out (Application of
In a relatively high cost economy such as overseas competitors to gain
Automation in UK Manufacturing,
the UK the application of automation advantage over them.
(computer controlled machines for
processing and handling products) is “Lack of flexibility is often perceived to be a
an essential ingredient in creating
barrier to investing in automation but Harwin design
sustainable manufacturing businesses.
The right investment in modern, and build special-purpose machines to meet this
automated manufacturing facilities will requirement. Without automated production the
enable businesses to achieve success in
company simply would not survive.”
Damon de Lazio, Chairman, Harwin
4
Case study The company has a turnover of
£12 million and employs 140 people.
it is necessary to use automated
assembly systems.
To remain competitive in an industry
Harwin – investing to Harwin design their own automation
which has well-established low-cost
compete internationally manufacturers in Asia, the company is
solutions and train their own staff to
meet their highly specialised needs.
Harwin design and manufacture constantly investing in updated
Lack of flexibility is often perceived to
world-class electrical and manufacturing technology. The main
be a barrier to investing in automation
electronic interconnect solutions, drivers are capacity to meet orders,
but Harwin design and build special-
supplying product designers and customer demands for the technology
purpose machines to meet this
OEMs worldwide with standard and for faster delivery, and cost.
requirement. Without automated
and custom products. Even with batches as low as ten,
production the company simply
would not survive.
5
The increasing uptake of automation In this increasingly competitive world
in countries with low labour costs, we need to improve our performance
such as India and China, demonstrates continually to achieve success. There is
automation is not about reducing a limit to what can be achieved by the
labour costs. While the use of labour application of efficiency measures if
undoubtedly provides businesses with operations continue to be based on
flexibility, its use also has cost implications. manual input. To drive improvements
further requires increased efficiency
Automation and particularly robots can
and consistency, in many cases this
provide a solution to ongoing business
is best achieved by the application
operating costs and can also respond
of automation.
flexibly to changes in volume demand
and product type.
6
Robots as an Indicator
Although robots are only one The use of robots within the automotive such as the USA at 74 and Japan at
element of automation they industry is fairly consistent across Europe. 235 robots per 10,000 employees.
provide a measurable indication of The table below provides a comparison
UK manufacturing has been much
levels of automation, and one that for all manufacturing sectors,
slower to adopt robots and automation
is reported internationally. excluding automotive.
than our competitors. To be successful
The International Federation of Robotics This demonstrates the remarkable lack of in the global market this needs to
report (World Robotics 2010) that robot utilisation in UK manufacturing change – now.
Germany has an installed base of when compared with competing
144,100 industrial robots, Italy 62,200, European countries. The UK also
France 34,100 and Spain 28,800 whereas compares unfavourably to other
the UK records only 13,900. international competitors,
140
127
120
114
100 97
80
60
45
40 38
25
20
0
Germany Sweden Italy Spain France UK
7
How Automation
Builds Businesses
Automation brings with it a increasing their level of automation • Removing the need for human
whole series of potential benefits suggests labour saving is not always the intervention in the more mundane
which improve the quality and main driver or benefit sought. Significant and repetitive tasks in manufacturing
productivity of a manufacturing benefits are often delivered that are not – freeing employees to work on other
process. However it needs to be envisaged at the start of the project such tasks which make better use of their
central to the business strategy as improvements in precision and capabilities and provide a better
tying in product design, reduction in waste. return against their costs
production, supply chain,
Improving Productivity • Achieving flexibility, allowing for quick
engineering, maintenance,
• Reducing the unit manufacturing changeovers leading to smaller batch
HR and management. sizes and reduced stock and work
cost by producing more with lower
Full automation is not appropriate in operating costs in progress
all instances and not all benefits apply
• Increasing the yield produced for a This provides for enhanced
to all situations. But appropriate and competitiveness, giving manufacturers
given resource input by ensuring
well applied automation will bring the ability to win more business both in
consistency of process and quality,
multiple gains. the UK and overseas, leading to business
thereby reducing costs
Typically many UK companies will assess growth and greater profitability.
• Ensuring utilisation of other
an investment in automation based on
equipment, such as machine tools, is
the planned labour savings. The fact that
maximised by reducing load/unload
countries such as China and India are
times and also by unmanned
operation, outside of normal shifts
8
“We don’t look at the desire or otherwise
to specifically develop automation.
Where there is a place for automation,
then we will go for it.”
Andrew Churchill, MD, J J Churchill
9
Improving Customer Improving Quality Improving Employee
Response and Service • Automation doesn’t tire during the day, Satisfaction and Performance
• The flexibility of automation makes it doesn’t lose concentration and doesn’t • Using automation in hazardous areas
fairly easy to increase and decrease make mistakes and for dangerous operations, not only
output in line with demand • Automation reduces damage or reduces the risk of accident but can also
fluctuations. For example, by breakages due to incorrect handling improve performance
running extended or weekend
• Automated processes result in less • Undertaking highly repetitive tasks,
shifts at limited additional cost
material waste and less rework, so leaving the more skilled activities to
• Automation can also enable rapid improving the yield humans, improves their job satisfaction
switchover between products to allow
The repeatability and consistency of Automation is often perceived to be a threat
for shorter runs and quicker, more automated processes allows the to jobs. Ultimately, as the Youngman case
frequent deliveries – offering a better maintenance of tighter tolerances, study illustrates, automation can make UK
customer response keeping product quality levels high and maunfacturing jobs more secure.
• The consistency of automation ensures cost minimised and resulting in
improved customer satisfaction and
the appropriate quality is maintained,
lower warranty costs.
ensuring customer satisfaction
10
Case study
Youngman – competing on
a global stage
The Youngman Group is a leading provider
of innovative, high quality access
equipment and systems, with turnover
exceeding £30 million.
11
Supporting the • Reducing scrap and rework and
Environmental Agenda improving yield, consequently reduces
• Operating in harsh conditions and at the energy used
greater extremes of temperature than
Not only does automation help reduce
humans, reduces the need to condition
the carbon footprint of individual
environments to the same degree
factories but by helping to keep
• Reducing space requirements, manufacturing local it reduces the
providing more compact facilities volume of goods being imported into
or producing more output from the UK and thereby reduces the energy
existing resources – removes the used to meet consumer demands.
need to expand
Case study
W & G Sissons – automated polishing
improves quality and increases output
Sissons, a leading producer of stainless steel catering
and sanitaryware, has installed an automated
polishing system significantly increasing productivity,
improving quality and reducing health and safety risks.
12
Case
study
Fosters Bakery –
increased capacity
and improved energy use
It is often a combination of factors
that provides the real benefit of
automation to a business.
energy saving of 50%.” Not only has the robot allowed Fosters to
Michael Taylor, Operations Director, Fosters increase production capacity by 80%, but it has
also provided an energy saving of 50%.
13
The Way Forward
To compete, today and in the The recently published report; our manufacturing companies and
future, requires investment. It is not Application of Automation in deliver the growth required to ensure
possible to succeed by continually UK Manufacturing, 27 Sept 2010 future prosperity.
squeezing more from the same (www.eama.info), which investigated
Awareness
operations and facilities. Many UK why the UK has such a low level of
Not enough is known, particularly within
businesses already have well- automation, identified three main
the UK SMEs, of what can be and has
organised and productive barriers to investment in automation,
been automated successfully elsewhere,
operations. This is an excellent typically faced by UK SMEs.
or of the costs and sometimes
starting point for the successful
Collectively, for UK plc, and within overwhelming benefits of doing it.
application of automation.
individual manufacturing companies
You need to find the best in class
If we are to increase our competitiveness there needs to be focus and
manufacturers in the world and use
and build sustainable businesses we commitment to overcome these
this as a starting point for planning
need to change our approach barriers. The investments need to be
the future.
to automation. made to secure the future of each of
14
Risk expectations are shorter – typically less
In many instances SMEs do not have the than two years when the plant may well
technical confidence to risk changing run for a minimum of five to ten years.
existing manufacturing systems and
Where all the benefits are evaluated in
have limited supplier and in-house
detail, including the threats from not
support to minimise these risks.
improving competitiveness, and
All parties within a company need to be analysed using a realistic return on
part of the process of automation and investment model the financial case can
the education that goes with it. be more compelling and less risky for
If you don’t have in-house expertise
contact one of the specialist groups
those providing the finance. Again
external assistance can be sought.
Case study
shown on back cover for guidance.
Skills Crown Products
Financing projects in the UK is typically There is a general lack of skills and enhances output and
more challenging as payback knowledge related to automation improves the working
particularly within the SMEs. This is environment
exacerbated by the lack of time faced
by most engineers forcing them to
Crown Products, established for
focus on day-to-day operations
over 60 years, manufactures
rather than improving their
kitchen and bedroom furniture
manufacturing operations. and employs around 90 staff.
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