The manufacturing industry is on the brink of a fourth industrial revolution as companies have begun experimenting with the disruptive potential of emerging technologies.
Credit: Comau
Credit: Comau
This transformation was accelerated by the Covid-19 pandemic, which highlighted the gaps in digitalisation, as companies were forced to adjust production lines to cater to rapidly changing supply and demand or, in the worst-case scenario, shut down production entirely where factories couldn’t operate under reduced staffing.
Nigel Hyland from industrial robotics and automation firm Comau, explains why British manufacturers can’t afford to lift their foot from the accelerator when it comes to digitalisation and automation in a post-pandemic world.
The Benefits of Digital Transformation
Experience shows that the manufacturing world can see a wide range of benefits from wider digital adoption. Businesses are already witnessing productivity gains, quality improvements, greater flexibility, and shorter times to market.
The most obvious of these is increased productivity. It is clear to anyone who has set foot on a factory floor that laborious and repetitive processes such as data entry can easily be undertaken by automated systems. But there is scope to go further, with technologies like predictive analytics, cognitive computing and artificial intelligence. These tools are already growing in popularity and serve not only to reduce the potential for human error but also to improve production line efficiency, freeing up employees’ time for more valuable work.
Digital tools like advanced vision systems for the detection of anomalies and quality control also allow for the collection and analysis of information, supporting preventative and predictive maintenance and optimisation, reducing cycle times, unexpected machine downtime and the risks associated with possible failures or the onset of the operational problems.
At a base level, businesses can maintain and repair equipment before larger issues develop, preventing costly breakdowns and unnecessary unscheduled upkeep.
These tools can also support employers in mitigating the kinds of labour shortages witnessed during the pandemic. Experts predict that the skills gap may leave 2.1 million manufacturing jobs unfilled between now and 2030. Embracing automation and digital tools can help to offset this by reducing manual workloads, making it easier to remain productive.
Barriers to Greater Digital Adoption
Despite the clear advantages that greater automation and digitalisation can bring, a significant number of businesses remain at the digital starting block.
According to the Digital Manufacturing Productivity Report from iBASEt, supported by The Manufacturing Technology Centre (MTC), 94% of UK manufacturers believe there has been underinvestment from businesses in digitalisation and that the UK has missed the early stages of a digital revolution, which risks inhibiting the ability of British employers to compete effectively on a global stage.
An alarming 93% also stated that this underinvestment could lead to many UK manufacturers ceasing to exist in the next 10 years.
So, what are the barriers to digital adoption and how can UK manufacturers accelerate the shift?
As the costs of doing business continue to rise, it is unsurprising that the largest obstacle is the fear of downtime associated with upgrades and budget constraints.
It is understandable that these have both affected business confidence and compromised long-term planning.
Nonetheless, as the use cases and benefits grow, businesses can’t afford to focus on the short term. There is a clear need here to embrace innovation and look to the cutting-edge tools the industry requires, rather than patching or modifying more generic systems that will ultimately cost more in time and money.
For this to happen, however, vendors must step up to the plate, too. We must work with companies to identify targeted needs and create digital transitions that can be delivered in small, manageable stages.
As an industry, we must also recognise that a lack of digital skills and technical knowledge also serves as an additional barrier.
While companies may be keen to explore the possibilities and advantages of these new technologies, they can’t do so without a workforce that has the necessary skills and knowledge to operate them. Upskilling and reskilling programmes therefore need to be a key focus. Luckily, there are a plethora of training solutions available for companies, individuals and schools that teach the technical competencies needed to reach industry 4.0 and close the skills gap. Investment in people will be as important as investment in technologies moving forwards.
The Opportunity for the UK
While some UK manufacturers have been slow to adopt digital technologies, the outlook is far from bleak.
The UK currently ranks in the top 10 largest manufacturing nations by the value of output and the manufacturing sector is charted to have a 6% growth for 2022 according to Make UK. But maintaining this strong position in the future will rely on a renewed focus on technology and the ability to digitise. While it is promising that 45% of manufacturers have introduced digital technologies. The findings also reveal that 15% of companies have no plans to do so by the end of 2023.
To remain competitive, the UK manufacturing sector must continue to cultivate and invest in emerging technologies.
Although the transition to Industry 4.0 is not yet completed, the foundations are beginning to be laid for the development of what it is emerging in the last year as the so-called Industry 5.0, bringing the concept of " automation as support for society.
The enabling technologies that have already begun to be introduced such as Digital twin models, cloud and Edge computing systems and IIoT services will become increasingly advanced and human-centred.
To survive and thrive in this rapidly evolving landscape, UK manufacturers must leverage automated and digital technologies and commit to upskilling their workforces or risk losing the competitive advantage
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