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Strengthening Service Support & Transforming Productivity… When reality meets remote diagnostics

An ounce of prevention is worth a pound of cure, said Benjamin Franklin over three centuries ago. Never has this sentiment been truer in today’s fast-paced production environments. Access to real-time information not only transforms service models and increases machine uptime, it also leads to better and faster business decisions, greater process transparency and higher productivity.

During the recent European Productivity Roadshow, visitors explored how three Sumitomo (SHI) Demag remote connectivity systems – activeConnect, myAssist and myConnect – are being deployed by customers to diagnose, troubleshoot and resolve issues faster. In addition to increasing machine availability and reliability, these remote service systems also inform better operational decisions and contribute to higher productivity. Without compromising security and sensitive data.

Marking this next phase in the evolving remote diagnostics and predictive maintenance journey, Sumitomo (SHI) Demag walked visitors through each connectivity option. Linking to the IntElect 75 ton production cell within the Roadshow truck, processors got the chance to view the support and diagnostic functionalities in a simulated ‘live’ production environment.

The uptick in interest for real-time remote machine monitoring has really started to accelerate, emphasised Technical Manager Nick Stockton during the four-stop tour of the UK and Ireland. Highlighting the user-friendly benefits of the my Connect option, Nick reaffirmed how this solution enables the company’s helpdesk experts to resolve issues faster and save money by connecting to a machine in the field.

Connectivity cost savings

Utilising cellular 4G and 5G networks, a private APN and encrypted VPN, more than 400 of the company’s injection moulding machines in the UK are now equipped with the activeConnect product developed by  Sumitomo (SHI) Demag UK. This PIA award-winning solution was intentionally designed to overcome the challenge of negotiating approval to access the company’s IT infrastructure. Something that many manufacturers with advanced IT architectures and firewalls prohibit. “Connection to the service management system is only established when the machine operative enables the system,” assures Nick.

Once connected to the machine, the company’s technical experts can observe, fault find, identify process problems and identify any required parts. Resulting in a first time fix rate of over 90%.

Quick to install, within minimal business interruption, Nick estimates that the annual subscription to connect four of their company machines on activeConnect costs the equivalent of an engineer’s average daily callout rate.  “This is a small price to pay for optimising productivity, maintaining operational efficiency, increasing machine availability and saving money,” emphasises Area Sales Manager Ashlee Gough.

Predict and protect

Similar to the SDUK activeConnect product, myConnect offers the same screen to screen connectivity, in addition to a more comprehensive and modular service support platform. It enables customers to integrate and capture data on their entire site production. For maximum security, myConnect connects to the central server via a secure VPN tunnel and places a request in the Sumitomo (SHI) Demag service messaging system.

The fully integrated ‘Site Controller’ within each machine enables various machine parameters to be called up and allows visualisation of production data at any time and from anywhere. Combined with myAssist, end users can define and access easy to read dashboards, consumption data and KPIs.

This level of high data transparency makes it possible to spot deviations, aggregate data captured from all OPC-UA filtered sources and react to changes in production processes at the earliest stage. The ability to merge data from multiple sources facilitates complete digital mapping of all production and environmental factors, including historical data. The addition of Human Virtual Interface (HVI) and an Expertise module to myAssist, also enables users to put data findings into context by adding labels and more detailed annotations.

“By analysing data from a variety of sources, customers can receive better predictive maintenance recommendations. This enables engineering managers to create maintenance plans to prevent unplanned breakdowns, in turn helping to protect assets by extending the lifecycle of machines,” adds Nick Stockton.

Download the company’s Make More For Less productivity whitepaper to discover how remote diagnostics can increase production yields and virtually eliminate machine downtime. https://sumitomo-shi-demag.co.uk/make-more-for-less

At the recent Productivity Roadshow, visitors explored how technologies like activeConnect, myAssist and myConnect can be deployed remotely to diagnose, troubleshoot and resolve issues faster.

Highlighting the importance of Industry Associations and Sponsorship

What a great story… so pleased to hear from Robert after all these years and to hear of his success .. we’re delighted to be back in touch with someone we’ve helped along the way..

I recently reached out to the PMMDA Trade Association, which sponsored me during my time at Coventry University 20 years ago. This sponsorship was awarded as a prize for winning a design competition while I was Product , Auto and Transport Design Coventry University. Reflecting on this experience, I recognised the importance of understanding the impact of such programs from an employer’s perspective.

My reflections culminated in an article featured as a column in British Plastics & Rubber magazine. Thank you to David Raine for the column and to the PMMDA Trade Association

Prepare to Automate: 6 Design Tips to Futureproof Your Production

Manufacturing is one of the UK’s success stories. With an output valued at £224bn, we are now the eighth largest manufacturing nation in the world. But our position is vulnerable unless we significantly increase our level of automation.

Helping manufacturers to increase their productivity, reduce waste, improve product quality and alleviate labour shortages, the benefits of automation are myriad. And as the only G7 country to sit outside the top 20 in terms of robot density (we are actually 25th in the IFR global robot league table), accelerating our automation uptake is essential if we are to retain our place as a leading manufacturing nation.

It is therefore important that when designing a new product, planning a new production line or upgrading your existing facility, automation is factored in from the very start of the process, not just as an afterthought. Not only does this keep down costs, it also ensures that any automation will be right first time, minimising downtime, boosting productivity and resulting in a solution that is fit for purpose.

Here, Oliver Selby, Head of Sales for FANUC UK, outlines six key design considerations for seamless automation integration…

  1. Embrace the automation process

It may sound obvious, but keep front of mind the fact that your product’s manufacturing process will need to benefit from automation. This can generally only be done by incorporating automation into the design of the product, whether that’s by giving the part a feature that allows it to be picked up by a robot, located or inspected by a vision system, or allowing access for a welding torch or fixturing, for example.

This mindset also translates to the wider production line. We see products designed using multiple materials, joining techniques and production methods which won’t all necessarily work together to produce something that is easily automated, but which designers are reluctant to give up. However, it can be better to take a hit on one material or process to make things easier to automate, thereby reducing overall production costs.  

  • Prioritise parts

Focus on part delivery methods within the complete solution. Often, customers will come to us looking for an automated solution, but with their component parts delivered in no ordered way. As much as 20-30% of the cost of the project can be spent on getting those parts located or fixtured and ready to process before the real automation process can actually begin. It makes more commercial sense to keep parts in order, whether that’s in a nested box, on a conveyor or in a stack.

Also think about part handling and fixturing. Significant costs could end up being channeled into part fixturing – even more so if you are working with a range of parts due to multiple fixtures. A good example of best practice here is to focus on one-way assembly; for example, where parts stack on top of each other to create the complete product or common part features that allow common fixturing.

  • Consider TCO

Concentrating on the wrong drivers for automation is a major error but one that we sadly see all too frequently. Some customers are more focused on fitting an automation solution into a defined payback period (often under two years) instead of looking at the value it will bring to the business over its lifetime. A total cost of ownership model is a far better measure. Purchase price only accounts for between 15-25% of the total cost of ownership; the remainder is made up of factors such as maintenance, energy usage, repairs, and even end of life. Measuring TCO rather than ROI will ensure you get the right automation solution for your business, resulting in real long-term value.

  • Remember the process, not just the consumer

It can be tempting when developing a new product to prioritise what’s easiest for the consumer, without realising that this may negatively impact the automation process. A prime example of this is shelf-ready packaging. The current trend within food manufacturing for front-facing packaging with tear-off flaps or loose fitting lids allows retailers quick and easy restocking of shelves. However, this seemingly simple change in packaging design has made it extremely difficult for automation to be exploited for end-of-line palletising, as the loose fitting lid or tear-off flap is not conducive to staying in place. Therefore, before making any packaging changes – no matter how seemingly minor – think carefully about how they may impact your ability to automate, and the effect this will have on production efficiency and labour demand.

  • Talk to automation suppliers

Engage with automation suppliers as early as possible. At FANUC, we are more than happy to support designers that are beginning their journey towards automation and will readily provide guidance on what the process is going to involve. We’ve done this countless times throughout the years as different sectors have started to embrace automation – from manufacturers of low-cost products to high-value goods; companies in the food industry; and more recently, with EV battery manufacturing for the automotive sector. We have rounded experience across lots of different applications within a wide range of industries that we are happy to share, and which designers can learn from.

  • Try before you buy

Finally, as in many industries, some automation suppliers are now starting to offer low-cost/low-risk routes into automation for companies taking their first steps into automation. Robots as a Service (RaaS) is a subscription-based option that enables manufacturers to pay a set fee over a specified period of time, and effectively lease a robot to use in their facility. The limitation of this offering is that it will only suit certain simple applications, for example, palletising, or particular welding options. The upside is that the robot can be repurposed for multiple product types – palletising a box of cakes is effectively the same process as palletising a box of dishwasher tables, for instance. Talk to your automation supplier to determine if RaaS could be right for your needs in the short-term – by allowing firms to test the water and experience the benefits before making their own investment, it can represent an affordable route into automation for some first-time users.


PlastikCity Launches Specialist Insurance Broker for the Plastics Industry

Online procurement and marketing hub PlastikCity has today announced the launch of PlastikCity Insurance, a new venture which offers tailored insurance solutions specifically designed for businesses operating within the plastics sector.

PlastikCity Insurance, in partnership with PHL Insurance Brokers Limited, provides comprehensive coverage options, competitive premiums, and dedicated service. With an in-depth understanding of the unique risks faced by plastic manufacturers, the new service ensures businesses receive the right policy from specialist insurers.

Comprehensive Insurance Solutions for Plastics Businesses

PlastikCity Insurance is committed to providing bespoke insurance solutions that cater to the unique needs of the plastics industry. The offerings include but are not limited to:

  • Property Insurance: Protects buildings, contents, machinery, and stock against a wide range of risks, ensuring business continuity in case of unexpected events.
  • Liability Insurance: Covers legal liabilities, including public, product, and employer’s liability, safeguarding businesses from potential claims and financial losses.
  • Business Interruption Insurance: Ensures businesses can maintain cash flow and operations in the event of unforeseen disruptions.
  • Cyber Insurance: Protects against cyber threats and data breaches, crucial for modern businesses relying on digital operations.

Expert Guidance and Tailored Policies

PlastikCity Insurance stands out by offering expert guidance and tailored policies. Each policy is crafted after a thorough assessment of the client’s specific requirements, ensuring comprehensive coverage without unnecessary costs. This personalised approach ensures that every business receives the most appropriate protection for its unique circumstances.

Competitive Premiums and Comprehensive Coverage

Working with specialist insurers, PlastikCity Insurance guarantees competitive premiums without compromising on coverage. The collaboration with PHL Insurance Brokers Limited, a well-established insurance broker with a proven track record, adds to the credibility and reliability of the services offered.

Unmatched Industry Knowledge

PlastikCity’s extensive experience in the plastics industry provides an unmatched understanding of the challenges and risks involved. This knowledge translates into more relevant and effective insurance solutions, making PlastikCity Insurance a valuable partner for any business in the sector.

Easy and Efficient Process

The process of obtaining a policy through PlastikCity Insurance is streamlined and efficient. Businesses can easily request a free quote through the dedicated website and receive a detailed assessment promptly. The team of experts is always available to provide support and answer any queries, ensuring a smooth and hassle-free experience. Additionally, for every quotation request sent through the website, PlastikCity Insurance will donate £25 to the Air Ambulance Service charity.

For more information or to request a free quote, visit PlastikCity Insurance or contact the team on insurance@plastikcity.co.uk.  

PMMDA welcome CARVECO as a NEW Member

Welcome to our latest member CARVECO, its great to have you on board, especially as we have a connection spanning over 20 years, we all look forward to working with you. Catch up with you soon at one of our events…

ABOUT US

The Carveco™ software range is the trusted CAD modelling and CNC machining solution to a multitude of industries worldwide.

The easy-to-use, yet immensely powerful, tools included in Carveco software give sign-makers, woodworkers, engravers, jewellers (and countless other creatives) the freedom to design and manufacture high-quality 2D or 3D products from their artwork, faster than they’d ever thought possible.

Robotics Innovation from FANUC boosts aerospace manufacturing output

In the face of unprecedented demand for new aircraft, robotics specialist FANUC is helping the aerospace industry to increase production efficiency and boost output. Over the past five years, FANUC has supported Airbus with its in-house robotics strategy, culminating in Airbus developing a robotic drilling system which employs a FANUC M-800iA/60 six-axis robot. The system has improved drilling accuracy and increased productivity for Airbus, while freeing up human employees to work on more creative and value-added tasks.

Breaking the order backlog

The start of this year (Q1 2024) saw the global aircraft order backlog hit record-breaking heights, reaching 15,812[1]. Automation and robotics are considered key levers to support this increasing demand. FANUC has long championed the use of its industrial robotic solutions as a way for aerospace manufacturers to boost production rates, streamline their operations and cut cycle times.

“Automation has become crucial in closing the gap on the backlog in aircraft orders as it significantly enhances production efficiency, reducing the time needed for manufacturing complex components,” says Oliver Selby, Head of Sales for FANUC UK. “Additionally, automation minimises human error and allows for more consistent quality control, ensuring faster turnaround times and enabling manufacturers to meet demand more effectively.”

Automating drilling tasks

Boasting advanced automation technology and an experienced team of robotics experts, FANUC was the ideal company to support Airbus in the development of its in-house robotics division. With its multiple drilling applications still largely completed manually, automating this process was a priority – but sourcing a robot that was robust enough to meet Airbus’ requirements initially proved a challenge.

“The specific solution that Airbus was looking for did not exist anywhere in the market,” explains Oliver. “The robot in question needed to be extremely rigid and stiff but also highly accurate, and with a minimum 60kg payload. We therefore worked together with Airbus to develop a prototype and refined this until it precisely matched their specifications for lower payload/small hole drilling.”

From prototype to production

This prototype has gone on to become the M-800iA/60 six-axis model, which is now part of FANUC’s standard industrial robot range. Also suitable for laser cutting, welding or other applications which require extremely high levels of accuracy, it offers outstanding precision without slowing down the production process.

Following rigorous testing and validation with FANUC, Airbus placed the first commercial order for the M800iA/60. The robot is now part of Airbus’ proprietary automated mobile drilling system. This system has now gone into production and represents the first of a new generation of robotic solutions for Airbus that have been custom designed by its in-house experts, with technical support provided by FANUC. Now on its way to being integrated into the A320 Family pre-assembly line, it adds value to Airbus’ manufacturing processes by reducing costs and stoppages, all while improving quality and saving time.

Reaping the rewards of robotics

Since the introduction of the M800iA/60 to the market, FANUC and Airbus have further developed the technology and implemented it into larger robots in the high accuracy/high stiffness range – 190kg and 270kg payload versions are now available, with a reach of 2m and 2.7m respectively. These additional FANUC robots could allow for further adoption in other applications within Airbus as they move to higher rate production to meet increasing global demand.

“There are numerous benefits to aerospace manufacturers of automating their drilling applications with the M800iA/60, including improved accuracy and repeatability, increased output, and better use of personnel for more value-added tasks,” states Oliver. “Longer term, the development of an in-house robotics division should also enhance the industry’s ability to attract high-level talent to technology-driven, innovative and future-ready companies.”

The future of aerospace manufacturing

Oliver continues: “From FANUC’s perspective, working with Airbus has been an extremely positive and rewarding experience. Showcasing the benefits of automation and robotics to the aerospace industry is vital in helping the sector to reduce the current backlog. This project demonstrates how important it is to collaborate with a robotics partner that will provide the right experience, knowledge, training and technology to support companies to achieve their commercial aims. We hope this will be the first of many such collaborations between FANUC and Airbus to increase efficiency within their manufacturing applications.”

To learn more about the future of aerospace manufacturing, visit FANUC on stand 4900 at the Farnborough International Airshow, 22-26 July 2024.


Deadline Extended for #PIA2024 to Monday 5th August

NEW for 2024! This award celebrates excellence in additive manufacturing solutions for the plastics industry. Created for businesses that are passionate about offering solutions for improving the efficiency, sustainability and productivity of manufacturing operations.

https://loom.ly/tjS9wrs

Who should enter : Companies that create new materials and processes as sustainable solutions for manufacturing in the plastics industry, which may include products, processes, integrations, softwares, materials etc

Please read the basic criteria information before entering to ensure your entry is eligible.

Congratulations to the Interplas 75 @ 75 Most Influential People

PMMDA are proud to Congratulate all of its members and committee who were listed as one of the Interplas 75 most influential people by 2023 receiving their awards.

This list of 75 individuals were deemed worthy by the industry itself, based on their significant contribution to advancing the UK plastics sector during the 75 years of the Interplas show.

Nominations were collected via a survey and out of hundreds of nominations, the 75 individuals are considered to have made a significant impact to the industry during this period.

Very humbled to have received this in the post yesterday .. thank you Interplas UK and a big thanks to whoever nominated me and voted for me .. 😊😊
PMMDA Trade Association

Nikki Williams, PMMDA Committee Secretary since 2008

Being part of the ##UKPLASTICS industry is a privilege. Being included and recognised alongside some of the industry’s key contributors is an honour.
thank you to Interplas UK and all have supported me throughout my career.

Richard Hird, UK Sales Director of Labotek GB Ltd and President of PMMDA

These have just arrived from Interplas UK. Gary and Ricky were acknowledged at Interplas last year as each being one of the 75 most influential people in the UK plastics industry. 👏

Gary Probert and Ricky Thompson, Hi-Tech Automation Ltd

A very proud Richard Perry with his dads award too, STV Machinery LTD

Mixed emotions having received these two plaques over the weekend. I’m extremely proud to have my name alongside my fathers on the list of 75 UK Plastics most influential people. It would have been great to stand next to him on that stage.

A huge thank you to Interplas UK and the people who voted for me. 😊🥰
This came as a huge overwhelming surprise, and I’m so proud to have been selected as one of the most influential 75 in the polymer industry over the last 75 years. True honour!

Darren Vater-Hutchison, Sumitomo (SHI) Demag UK Ltd

🔥

A huge congratulations to Lee Thomas 🔥

We are delighted to have received this beautiful award to add to the collection! Lee Thomas has been recognised in the Interplas UK 75@75 list of top influencers in the plastics industry. His hard work and commitment to providing top-of-the-range equipment and service to the plastics industry deserve to be celebrated.

TH Plastics Ltd

What a fantastic surprise on return from a holiday.
After working in this industry for 46 years, I have to say that I am extremely pleased and proud to have been nominated as one of the 75@75. Thank you to Interplas and those that nominated me.

Colin Tirel, MD of Arburg Limited

POWER TO PACKAGING: WHY LESS NOW DELIVERS MORE

Luxury packaging plays a critical role in delivering a consumer touch-point experience. However, all mass-produced packaging that serves a functional handling and storage purpose should be given equal attention.

For many consumable products across the value chain, minimalist polymer packaging that delivers a protective shield to safeguard against waste can help to enhance the non-verbal message of sustainability. Symbolically, if packaging items are also processed in the most energy efficient way with less machine downtime, close to zero rejects, and where feasible using recyclable polymers, this unquestionably strengthens the whole lifecycle narrative.

The on-going innovations happening in injection moulding are indicative of just how much sustainable value is aligned to current and future packaging trends and the interlinked dependencies on system efficiencies. With non-recyclable packaging set to be banned by the EU by 2030, UK packaging expert and regional sales manager Ashlee Gough explains why Sumitomo (SHI) Demag is intentionally focusing its efforts on supporting fast-cycling packaging manufacturers to more than halve energy consumption.

Manufacturing packaging has always been about balancing processing speed with cost. Now, the sector is also tasked with reducing environmental impact. With many high-end customers pushing to shift to an all-electric production model, Sumitomo (SHI) Demag has invested a lot of time and energy in creating a machinery collection that fuses the company’s all-electric drive technology, processing speed and energy-enhancing features.

“Fluctuating energy costs creates uncertainty. Particularly for packaging manufacturers where energy is the highest and most unpredictable expense. To counteract this, fast processing repeatability and reduced waste, combined with halving energy costs is now deemed imperative,” explains Ashlee.

Switching to all-electric sounds simple enough. Yet, when you have a model that’s been revered for its speed as much as the company’s hybrid packaging El-Exis series, accomplishing this takes time.

Processing speed has been the biggest hurdle to overcome.

“The challenge for any company is always going to be bringing a packaging machine to market that produces components just as fast, if not faster, without compromising cycle time, service life or energy use,” adds UK Managing Director Dave Raine.

Maintaining repeatability, speed and precision while simultaneously improving energy efficiency by utilising direct drive technology underpins the Group’s packaging strategy. Until recently, matching the force and speed of hybrid packaging machines was inconceivable. But, with 80,000+ all-electric machines now installed globally, Sumitomo (SHI) Demag has fused all their market expertise with application knowledge to edge ahead and give packaging processors the blend of productivity, reliability, and energy savings.

It is all down to Sumitomo’s in-house direct drive technology, emphasises Ashlee. “As each individual axis has a drive that has been developed specifically for each function, it means that packaging processors can achieve faster cycle time plus energy savings of up to 70 percent when compared to hydraulic machines.”

For the past decade, the El-Exis SP set the benchmark in energy consumption for machines operating a 2 second cycle time. PAC-E matches this speed and achieves the same injection dynamics, yet halves the energy consumption. Also filling a critical gap, the company’s latest IntElect S machine is geared specifically towards plastic processors mass-manufacturing narrow tolerance and thin-walled packaging lids and containers at the fastest speeds.

Both machines have been designed to incorporate future digital product passport technology. “As an active member of the R-Cycle community, being able to offer this interoperable software will go a long way towards supporting plastic traceability and the drive towards larger carbon reductions right across the value chain,” adds Dave Raine.

Around 90 percent of the machines installed annually by Sumitomo (SHI) Demag are now all-electric. The company estimates that a third of these are now used by packaging processors to produce caps, closures, lids and containers used by the consumer, medical and food sectors. “These technological advances opens up the associated benefits of the all-electric moulding machine market to even more packaging applications,” ends Ashlee.

The new PAC-E machine features an all-electric drive, saving packaging processors 50 percent or more in energy when measured against a high-speed hybrid packaging machine


By expanding the IntElect S series, Sumitomo (SHI) Demag opens up the associated benefits of the all-electric moulding machine market to even more thin-walled packaging applications