NEWS | FEATURES | PRODUCTS | CASE STUDIES October/November 2024 |Issue 483 www.pwemag.co.uk @PWEmagazine1 From local roots to global reach Inside this issue: 12 > Roadmap to IoT Success with legacy manufacturing equipment 24 > Boosting industrial efficiency through energy audits 26 > Addressing the skills gap in the face of climate change page 32 @plant-&-works-engineering PWE Plant & Works Engineering Since 1981
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One of the most prominent concerns highlighted in the report is the acute shortage of skilled labour in maintenance roles. Skills shortage tops maintenance challenges The recent released ‘Performance in Focus’ 2024 Maintenance Engineering Report by RS, in collaboration with the Institution of Mechanical Engineers (IMechE), offers significant insights into the evolving challenges faced by maintenance professionals across the UK and Ireland (read the full news story on page 6). Based on responses from nearly 400 maintenance professionals working in sectors such as manufacturing, energy, and intralogistics, the report sheds light on key industry issues ranging from talent shortages to the management of unscheduled downtime. One of the most prominent concerns highlighted in the report is the acute shortage of skilled labour in maintenance roles. This has become the top issue for the industry in 2024, with half of respondents identifying it as a Editor’s Comment ‘ ’ pressing concern. It is clear that the engineering sector must work harder to attract and develop talent, with apprenticeships and targeted skills training emerging as essential components of the solution. As Lydia Amarquaye from IMechE points out, a concerted effort is needed from both industry and educational institutions to raise the profile of engineering and highlight the importance of maintenance within the broader field. Technological evolution is another key theme explored in the report, particularly the growing reliance on data analysis to optimise maintenance strategies. However, many organisations still rely on outdated methods such as paper records (59%) and Excel spreadsheets (37%), indicating that many are lagging behind in adopting more advanced tools. While the use of computerised maintenance management systems (CMMS) has increased, with 62% of organisations now utilising such systems, the report shows that only 22% have adopted enterprise asset management systems, down from 39% in the previous year. This suggests a gap in the sector’s ability to fully integrate advanced digital solutions into everyday operations. Unscheduled downtime remains a persistent challenge, with maintenance teams averaging 15 hours a week managing breakdowns. Although this marks a reduction from the previous year, the financial impact remains substantial, with the average cost of downtime rising to £5471.95 per hour. Ageing assets and mechanical failures are the primary causes, underscoring the need for proactive asset management strategies. The report’s findings suggest that organisations are increasingly adopting preventative measures, such as upgrading equipment and enhancing training, to combat these issues. However, as Raj Patel, managing director of RS UK & Ireland, notes, there is still room for improvement in the maturity of maintenance practices across the industry. Leveraging supplier expertise and outsourcing specialist tasks may provide a valuable means of addressing both skills shortages and the demands of modern maintenance. October/November 2024 www.pwemag.co.uk Plant & Works Engineering | 03
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October/November 2024 www.pwemag.co.uk Plant & Works Engineering | 05 Editor: Aaron Blutstein t| 01732 370340 e| editorial@dfamedia.co.uk Content Sub Editor: Leslah Garland t| 01732 370340 e| leslah.garland@dfamedia.co.uk Sales Director and DFA Direct: Damien Oxlee t| 01732 370342 e| damien.oxlee@dfamedia.co.uk Sales Manager: Andrew Jell t| 01732 370347 e| andrew.jell@dfamedia.co.uk Production Manager & Designer: Chris Davis e| chris.davis@dfamedia.co.uk Marketing Manager: Hope Jepson e| hope.jepson@dfamedia.co.uk Operations Manager: Emma Godden-Wood t| 01732 370340 e| emma.godden-wood@dfamedia.co.uk Reader/Circulation Enquiries: Perception t| +44 (0) 1825 701520 e| cs@perception-sas.com Financial: Finance Department e| accounts@dfamedia.co.uk Managing Director: Ryan Fuller e| ryan.fuller@dfamedia.co.uk Published by: DFA Media Group 192 The High Street, Tonbridge, Kent TN9 1BE t| 01732 370340 e| info@dfamedia.co.uk w| www.pwemag.co.uk Official Supporters: Printer: Warners, UK © Copyright 2024, DFA Manufacturing Media Ltd ISSN 0262-0227 PWE is a controlled circulation magazine, published 11 times a year. Please contact DFA Media with any subscription enquiries. Paid subscriptions are also available on an annual basis at £100.00 (UK) or £170.00 (Overseas) P+P included. The content of this magazine, website and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. COMMENT 3 NEWS 6 A round-up of what’s happening in industry. INSIGHT 10 MAINTENANCE MATTERS - INCORPORATING PROBLEM SOLVER 12 Focus on: Maintenance 4.0/ Condition Monitoring Lynn Loughmiller takes a closer look at how IoT can be an effective tool when working with existing equipment, and looking at just how efficient it may be. PROCESS, CONTROLS, & PLANT 20 Focus on: Compressed Air/ Pumps & Valves Libby Peacock, a compressed air specialist at Rubix, has highlighted the significant financial challenges faced by production facilities across Europe due to air leakage. She emphasises that this often-overlooked issue can lead to substantial financial losses as well as serious environmental consequences. ENERGY & ENVIRONMENTAL MANAGEMENT 26 Focus on: Boilers, Burners & Controls/ Cooling A recent Institution of Engineering and Technology (IET) survey reveals a significant skills gap in the engineering sector, particularly in the context of addressing climate change. While many UK employers are taking steps to reduce their environmental impact, there is widespread concern about the lack of necessary skills and training within the workforce. Etienne Fourie, Technical Sales Manager at Babcock Wanson, takes a closer look. HANDLING & SAFETY MATTERS 32 Focus on: Handling & Storage Few stories in manufacturing exemplify innovation and perseverance as effectively as that of Combilift. Martin McVicar, the co-founder and CEO, recently received the prestigious title of Irish Exporter of the Year, a reflection of the company's remarkable journey since its establishment in 1998. PWE reports. SPECIAL FOCUS INDUSTRIAL SECURITY 36 ADVANCED ENGINEERING PREVIEW 38 SUPPLY CHAIN 40 PRODUCTS & SERVICES DIRECTORY 42 Contents 12 32 20 26 BCAS official media partner Subscribe for your FREE copy now
News 6 | Plant & Works Engineering www.pwemag.co.uk October/November 2024 RS, a digitally enabled global distributor of product and service solutions for industrial customers, has released the ‘Performance in Focus’ 2024 Maintenance Engineering Report in conjunction with the Institution of Mechanical Engineers (IMechE). This is based on findings from a survey that aimed to uncover the challenges facing the profession and its priorities. The survey drew responses from almost 400 maintenance professionals based in the UK and Ireland. The respondents were from sectors including manufacturing, working in job roles like maintenance engineer and engineering manager. Most respondents came from hands-on or operational roles, working in sectors including facilities and intralogistics, manufacturing, energy, and oil and gas. The resulting report covers key areas including challenges, strategies and priorities, maintenance maturity and data, and tackling unscheduled downtime. While attracting talent was a top three issue for maintenance engineers in the 2023 report, staffing fears have risen to the top of the agenda for 2024, with half of respondents now citing this as a prominent concern. More than a third (37%) point to this as their top challenge, rising to 42% for larger organisations. Lydia Amarquaye, education and skills policy lead at the IMechE, isn’t surprised that skills have risen up the agenda and cites a need to work together to get more people into engineering. She said: “We need to raise the profile of engineering in schools and help to raise the profile of maintenance, in particular, as a valued part of the mix. Industry needs to take responsibility for developing talent, including developing apprenticeships and helping graduates who join with a broad skill set to gain specific skills for their particular industry.” With a growing requirement for data analysis in the quest for more effective maintenance strategies, lack of data interpretation capabilities presents a challenge. The skill set of the current engineering pool appears not to be catching up with evolving technology. The report highlighted an increased reliance on Excel spreadsheets and paper records, with 37% and 59% respectively saying they are still used in-house. But while paper and manual records are on the rise, the report showed that 62% of organisations use computerised maintenance management systems (CMMS) – up from 49% the year before – and the use of Excel spreadsheets is most common among firms with low levels of maturity. Only one in five (22%) use enterprise asset management systems, down from 39% in 2023’s report. The nightmare scenario of unscheduled downtime is still all too common, with the average organisation spending 15 hours a week battling it, down from 20 hours last year. This is down by a quarter on last year’s figures, which is mildly encouraging. However, it still accounts for 24 hours a week for more than one in five (21%) of organisations. The average hourly cost of downtime was higher this year at £5471.95 (£5121.81 last year). The biggest single cause of unscheduled downtime was cited as ageing assets, by 29% of respondents, followed by mechanical failure, cited by 21% of respondents. Managing ageing assets is an ongoing challenge for maintenance professionals, according to Richard Jeffers, solutions and technical director at RS: “Businesses don't want to replace assets simply because they’ve reached a certain age and, as maintenance professionals, they should be focused on how they can maximise the life of an asset, which can increase cash flow for the business.” The survey findings highlighted that organisations are taking steps to reduce unscheduled downtime, the most common strategies being upgrading equipment and improving training (both 49%), plans to introduce a preventative maintenance strategy (40%) and a change in approach towards maintenance (30%). Raj Patel, RS UK & Ireland managing director, said: “Modern maintenance professionals face a tricky balancing act between the day-to-day realities of ensuring facilities are safe and operational, and longer-term projects designed to prevent future breakdowns or inefficiencies. “It was encouraging to see organisations are deploying a variety of strategies to help reduce unscheduled downtime in the report. But there’s a wide spectrum of results here in terms of maintenance maturity and there’s still clearly a way to go. Maintenance professionals should seek to leverage suppliers for both reliability and quality of parts supply, and solutions providers to outsource elements of maintenance, particularly if the required specialist skills aren’t available in-house.” RS releases ‘Performance in Focus’ 2024 maintenance engineering report
News October/November 2024 www.pwemag.co.uk Plant & Works Engineering | 07 Sir Chris Bryant MP, Minister of State at the Department for Science, Innovation and Technology and the Department for Culture, Media and Sport, recently visited the new Digital Catapult 5G Immersive Lab in Newcastle, exploring the facility that will enable companies in the North East to scale faster. The state-of-the-art innovation lab, based in Newcastle’s Eldon Square, will help SMEs to de-risk the adoption of 5G and immersive technologies, accelerating the practical application of deep tech across key industries. The facility will encourage SMEs to work alongside large businesses, developing proofs of concept that can solve complex business challenges. Digital Catapult is encouraging businesses in the North East from traditional industries including retail, agriculture and manufacturing, to engage with the lab, providing them with pioneering new technologies, enhanced 5G capabilities from Vodafone 5GSA, and access to expertise from Digital Catapult’s team. During the visit, the Minister explored the work of leading regional companies that are developing transformative solutions across consumer and training experiences. A futuristic augmented reality (AR) showcase, presented by local tech company Aircards, allowed the Minister to interact with the latest in ‘smart mirror’ technologies. The Minister also experienced a virtual hazard-perception training exercise created by fellow North East innovator Luminous XR, which has presented to several participants on Digital Catapult’s programmes. With a view to boosting digital skills, productivity and innovation across the North East region, Sir Chris Bryant’s visit follows the Labour Party Conference, where the Minister made clear the ambition to improve connectivity across the country. Digital Catapult’s 5G Immersive Lab opened by UK Tech Minister New five strategies guide to enhancing MRO efficiency ERIKS, a leading specialised industrial service provider, has released a new guide designed to help manufacturers streamline their MRO operations. The guide, called 5 ways to enhance your Maintenance, Repair and Operations (MRO) supply chain, offers practical strategies to improve procurement, storeroom discipline, data management, and operational efficiency in the face of evolving industrial challenges. In light of recent disruptions, such as Brexit, COVID-19, and global geopolitical tensions, the guide addresses the critical need for resilient and responsive MRO practices. By adopting the five strategies businesses can better navigate these complexities, ensuring they remain competitive and operationally efficient. Commenting on the launch, Nathan Cutler, Chief Business Development Officer, ERIKS Industrial Services said, “In today’s rapidly changing industrial environment, efficient MRO management is more important than ever. Our new guide provides simple, actionable insights that can significantly enhance the resilience and effectiveness of MRO operations, helping businesses to optimise their processes and reduce downtime.” The new guide addresses five critical areas. It begins by emphasising the importance of prioritising critical components, ensuring that businesses can maintain operational continuity even in the most resourceconstrained environments. Another key focus of the guide is data management. ERIKS highlights the need for streamlined and accurate data to support decisionmaking processes within MRO operations. Proper data management not only reduces the risk of stockouts but also enhances overall operational efficiency by providing a clear view of inventory levels and needs. Managing obsolescence is also covered, with proactive strategies to identify and mitigate the risks associated with outdated or soon-to-be-unavailable components. The guide suggests leveraging predictive analytics and regular reviews to ensure that businesses are not caught off guard by unexpected shortages. ERIKS also explores innovative procurement models that address the inefficiencies often found in traditional MRO purchasing processes. By adopting more agile procurement strategies, businesses can reduce unnecessary spending and better manage their inventory levels. Finally, the guide underscores the importance of building strong relationships with MRO supply chain experts, emphasising the value of suppliers who can act as strategic partners to businesses and contribute to their continuous improvement efforts. By drawing on extensive technical knowledge and industry expertise, such suppliers can support manufacturers in refining their maintenance operations, improving efficiency, and addressing the evolving challenges of modern industrial environments.
News 08 | Plant & Works Engineering www.pwemag.co.uk October/November 2024 The Government recently published its Green Paper on Industrial Strategy which is a major part of its plans to boost the growth potential of the economy over the long term. Make UK has long campaigned for a long-term industrial strategy and its to be hoped that the publication of the paper will herald the start of a cross Government on critical areas. The paper was in three parts. Firstly, it covered a sectoral approach focusing on professional services, advanced manufacturing, life sciences, clean energy and transport and the creative industries. Secondly it covered Places with the intention of driving growth and investment across all areas of the UK. Third, it covered cross cutting initiatives in policy areas such as skills, energy, infrastructure, innovation and digital adoption. The introduction of an industrial strategy also has the potential to bring other benefits. According to a major annual survey on the investment landscape for UK manufacturing published at the same time by Make UK almost three quarters of companies (70%) would accelerate the re-shoring of production back to the UK in response to an industrial strategy, with just 3% saying it would make no difference to their location of production. Furthermore, half of companies would increase investment in existing facilities in the UK, while almost a third (30%) would increase automation and increase exports to the EU (29%). Just 1% of companies said the introduction of an industrial strategy would have no impact on their business at all. At a time when global supply chains are changing to a just in case scenario rather than just in case, such a shift in production has the potential to massively increase the self-sufficiency and resilience of production in the UK. Manufacturers are poised at the starting blocks for the Government to unleash the benefits to investment that firing the starting gun on a long-awaited industrial strategy will bring. It’s clear that this will bring a wide range of benefits and aid companies who are accelerating their moves into greater use of automation and digital technologies, with the increased recruitment of higher-level skills. Given the US, Europe and China are moving at pace with plans to boost investment in green technologies in particular, the UK needs to match these efforts step for step. The publication of the Green Paper on Industrial Strategy is a welcome first start. By MAKE UK chief executive, Stephen Phipson MAKE uk - the manufacturers’ organisation monthly news comment BARA (the British Automation and Robotics Association) has named FANUC UK’s Head of Sales, Oliver Selby, as its new Chair. Taking over from current Chair George Thompson, Selby will be supported in his new role by Vice-Chair Rosie Davies from Reeco Automation. Part of Automate UK, BARA’s remit is to promote and support the development and adoption of industrial robots and automation in the UK, providing a voice to government, industry and academia. With more than 20 years’ experience, Selby is a longstanding and vocal supporter of the UK automation sector, and of manufacturing more widely. In his role as Chair, he plans to drive the association’s activities forward, supporting BARA’s aim to increase automation uptake while placing members’ needs firmly front and centre. Peter Williamson, CEO of Automate UK, commented: “Oliver is an influential voice within the industry, his passion for all things manufacturing, automation adoption and future skills, will be a key factor in developing BARA alongside the existing committee, and with the full support of Automate UK.” One of Selby’s key pledges is to ensure the association delivers real value to its members: “I am excited to bring my knowledge, influence and passion for automation to a wider audience, and will be fully focused on delivering value to all facets of the BARA membership and other stakeholders – from OEM robot manufacturers and system integrators to companies in the supply chain, academic institutions and High Value Manufacturing Catapults. “It has been widely reported that, despite our status as a leading manufacturing nation, the UK is still lagging behind the rest of the world when it comes to automation adoption. Communicating the myriad benefits that automation can bring, including through events such as Automation UK (7-8 May 2025, CBS Arena, Coventry) is key to increasing uptake. It is essential that we highlight how automation can alleviate manufacturers’ key challenges by helping to mitigate labour shortages, increase productivity, boost sustainability credentials, and cut operational costs.” Selby added: “However, it is also important to understand the challenges that manufacturers – particular SMEs – are facing. At BARA, we will strive to offer the right tools to manufacturers of all sizes, to ensure they can make the right automation choice for their business, with the right partners, and with the right technology, to futureproof their manufacturing operations as risk-free as possible. New BARA Chair announced
NEW INNOVATIVE CONTROLLER UPGRADE TO HBP-ZL AIR DRYER AIR-TREATMENT For many years Hi-Line’s HBP (Hi-Line Blower Programme) has been revered as the compressed air industries most energy efficient adsorption dryer. This summer, Hi-Line’s technical department, headed up by Darren Sims, has added some incredible energy saving technology to the controller, including Internet of Things technology as well as remote access service support. Over the past 25-years, Hi-Line Industries has developed a muchadmired range of energy efficient compressed air treatment products from its UK-based factories in Burton-upon-Trent, in the heart of the nation. The flagship product, and the jewel in the crown, is its HBP range - the first product to be designed and manufactured back in 1999. A few years later the HBP-ZL was created, ZL being the suffix for zero loss - a high-capacity air dryer that uses zero compressed air. Unlike others available at the time, it was a genuine zero loss driver. The regeneration cycle uses no compressed air and can be regenerated using an electrical external heater and a bi-directional fan, with additional regeneration sources of steam, heat of recovery, and solar. Twin Tower technology has been around for as long as I have, and yes, whilst the vessel technology is important in terms of contact time, velocity and zeolite choice, the clever part of the HBP dryer is in its controller. Just like any energy, controlling that energy is key. Hi-Line dryers have always been the most energy efficient dryers that money can buy. The HBP control panel has sensors transducers, probes, temperature controller, placed on all aspects of the vessel, measuring incoming air flow, temperature, relative humidity and pressure dewpoint. It is continually making automatic changes to the dryer performance to ensure it is constantly changing the energy/regeneration air, ensuring the HBP is always performing at its optimum. For the past fourteen months, Hi-Line has teamed up with Siemens to look at putting additional software into its dryer panels in order to monitor all our dryers in the field. Access is available to customers via desktop and mobile apps to inform dryer duty cycle status, service life, dewpoint and energy consumed and time sport on standby. This new “TALK TO ME" technology is currently available on all new HBP dryers and can be retrofitted to Hi-Line dryers that are already in the field. It can also be fitted to competitors’ dryers which are not as energy efficient in order to increase the performance without replacing the whole dryer. This technology is also now available on our Atacama range of dryers with the new HDC2 controller. Hi-Line is offering a free site survey to offer this innovative technology to customers throughout the UK. With a new Hi-flow range of flanged filters, Hi-Line continues to build the most competitively priced air dryers operating with energy performance and control at the forefront. Steve Smith, Managing Director, HI-LINE INDUSTRIES MOTATEST 1 MULTI FUNCTION TESTER All-purpose tester for testing electric motors and products with windings whitelegg.com Call us now: +44 (0) 1293 526 230 MOTATEST 2 3KV MULTI FUNCTION SURGE TESTER A truly universal tester delivering truly remarkable bene ts, with special test functions for DC motors NEW MTC2 R7 AUTOMATIC ELECTRIC MOTOR ANALYSER Measure the motor’s performance with special analysis software to give a complete picture Supporting motor manufacturing, test and repair with expertise and world beating machinery and instruments, Whitelegg can advise on the best solution for your project. NO FAULT HERE... Electric motor analysers from Whitelegg Machines
10 | Plant & Works Engineering www.pwemag.co.uk October/November 2024 Insight While effective maintenance strategies and regimes rightly take centre stage for plant engineers and reliability teams, a new industry report emphasises that optimising the supporting MRO (maintenance, repair, and operations) supply chain should also be a crucial priority. The MRO Supply Chain Report 2024 highlights the significant impact of MRO supply chain challenges on maintenance regimes and overall operational efficiency. The report paints a stark picture of the current state of skills in the maintenance industry. Experienced engineers are increasingly hard to find, and this scarcity is reflected in the small sizes of maintenance teams. According to the report, 67% of maintenance teams consist of fewer than 10 people, while 70% of engineering stores departments have under 4 staff members. This shortage of skilled personnel forces engineers to take on roles outside their core responsibilities, including involvement in MRO procurement and managing engineering stores. The lack of specialised skills in these critical areas can lead to inefficiencies and increased downtime. With small teams stretched thin, there is little time for training or knowledge transfer to less experienced colleagues, exacerbating the skills gap. To mitigate these challenges, many businesses are turning to outsourcing. Outsourcing allows companies to leverage the expertise of vendors who can offer both technical and supply chain knowledge, enabling engineers to focus on their primary tasks and reducing the strain on limited in-house resources. Moreover, the report highlights that 10% of businesses have resorted to involving engineers in stores duties due to the acute shortage of resources. This practice not only diverts engineers from their core tasks but also Report reveals key strategies for boosting maintenance efficiency A new industry report underscores the critical importance of optimising MRO (maintenance, repair, and operations) supply chains to enhance maintenance strategies and operational efficiency. PWE explores the key findings, focusing on the implications for maintenance professionals and offering strategies to optimise maintenance practices through improved MRO supply chain management.
Insight October/November 2024 www.pwemag.co.uk Plant & Works Engineering | 11 indicates a critical need for better resource allocation and management within the MRO supply chain. Financial impact The financial implications of poorly managed MRO inventory are significant. The report reveals that over half (51%) of UK manufacturers experienced unplanned downtime in the past year due to spare parts availability issues. This downtime translates directly into lost production time and financial loss. The trend of stockpiling MRO inventory as a buffer against supply chain disruptions has led to substantial financial burdens. The average UK manufacturer now holds £730,681 worth of MRO inventory, a figure that has increased dramatically since 2019. Despite the large stockpiles, many businesses struggle with inventory management, leading to high levels of obsolescence. Over 50% of respondents could not provide data on the value of engineering inventory written off in the last financial year due to obsolescence. The frequency of regular stock checks and cycle counts has also declined, with 30% of businesses never performing full inventory audits. These practices result in excessive write-offs and inflate carrying costs, further draining profitability. There is also the possibility that many businesses are storing up something of a ‘write off timebomb’ which, when its full impact is exposed, will have serious implications for their financial reporting. The report underscores the need for businesses to adopt more disciplined inventory management practices. The decline in regular stock checks and the prevalence of obsolescence highlight a significant area for improvement. Implementing more frequent cycle counts and leveraging technology for inventory management can help businesses maintain accurate stock levels, reduce writeoffs, and optimise carrying costs. Procurement challenges One of the most striking findings from the report is the prevalence of "squirrel stores"— unofficial stashes of parts kept by engineers and technicians. A startling 55% of respondents admitted to having such stores, highlighting a significant trust issue with official procurement and stores processes. These squirrel stores undermine data integrity and complicate inventory management. Additionally, the involvement of engineers in procurement activities, driven by the lack of dedicated resources in engineering stores, further complicates the procurement process. Engineers often do not have the necessary procurement expertise, leading to inefficiencies and potential errors. The report encourages a more structured approach to procurement, with clearer roles and responsibilities to ensure that engineers can focus on their core tasks while the MRO stores team and the procurement team work in sync to handle purchasing. The report also highlights that the "squirrel stores" phenomenon is symptomatic of deeper issues within the procurement process. Engineers’ lack of trust in the procurement team and the perceived inefficiency of the stores system drive them to create these unofficial stores. By addressing these underlying issues and implementing more efficient inventory management systems, businesses can improve trust in the official processes and reduce the need for such workaround solutions. Performance measurement The performance of engineering stores is often measured using backward-looking metrics such as work order completion rates and stock availability. While these metrics are important, they do not capture the full potential of what a well-managed MRO supply chain can offer. The report highlights the need for more innovative and proactive performance measures that focus on technical expertise and supply chain insight. For instance, the time taken to source and order a non-stocked spare part is a critical metric that directly impacts downtime. The report found that sourcing such parts often takes days, causing significant production delays. By integrating supply chain knowledge and technical expertise into the engineering store's function, businesses can reduce these delays and improve overall efficiency. The report suggests that engineering stores should not just be measured on traditional metrics but also on their ability to add value through technical and supply chain insights. For example, the MRO stores team can play a crucial role in suggesting alternative parts or suppliers, thus reducing lead times and costs. Businesses that harness the full potential of their MRO stores team can significantly enhance their operational efficiency and reduce downtime. Business impact Aligning maintenance strategies with MRO procurement and engineering stores operations can have a profound impact on reducing downtime and enhancing profitability. The report emphasises that issues related to the MRO supply chain and engineering stores are major causes of downtime. By addressing these issues holistically, businesses can gain valuable insights into the root causes of downtime and implement measures to prevent it. There is no one-size-fits-all solution to these challenges, but a well-coordinated approach that aligns maintenance strategies with MRO procurement and engineering stores operations can lead to significant improvements. For example, adopting predictive maintenance strategies and leveraging data analytics can help businesses anticipate spare parts needs and reduce unplanned downtime. The findings also highlight the importance of viewing the MRO supply chain as an integral part of the overall maintenance strategy. By integrating MRO practices with maintenance programmes, businesses can create a more resilient and efficient operational framework. This integration helps in ensuring that the right parts are available when needed, thus reducing downtime and improving overall productivity. The MRO Supply Chain Report 2024 from ERIKS UK & Ireland provides crucial insights into the challenges faced by UK manufacturers in managing their MRO supply chain. For maintenance professionals, the report underscores the importance of addressing skills shortages, improving inventory management, and optimising procurement processes. By aligning maintenance strategies with MRO procurement and engineering stores operations, businesses can reduce downtime, enhance efficiency, and ultimately increase profitability. To download the report in full, visit https://eriks.co.uk/en/know-howhub/news/eriks-mro-supply-chain-report
Maintenance Matters Focus on: Maintenance 4.0 12 | Plant & Works Engineering www.pwemag.co.uk October/November 2024 Lynn Loughmiller, Software Engineering Manager at DELMIAWorks, takes a closer look at how IoT can be an effective tool when working with existing equipment, and looking at just how efficient it may be. Smart machines can provide manufacturers with invaluable real-time insights into shop floor productivity, inventory, and potential quality and maintenance issues. But buying new machinery to harness the Internet of Things (IoT) can be hard to justify, especially when interest rates remain high. An effective option to IoT success is to add sensors to existing equipment and start capturing real-time data at a fraction of the cost. Selecting sensors Available sensors support different types of data collection that enable manufacturers to track metrics related to productivity, consumption, wear, and other factors. Here are five commonly used sensors. • A proximity sensor is used for counting. One sensor may capture each part produced. Another may track the feet of material going into the machine. Comparing those two measures can help to understand scrap and percentage of loss. • Amperage and pressure sensors work similarly. Amperage sensors can measure machine speed and force of tooling. Pressure sensors capture similar information for hydraulic-based machines. Having a standard base of amperages and pressures for each part can determine proper setup, tooling expectations, and machine norms. Meanwhile, variations from base measurements can indicate issues affecting part quality or equipment maintenance. • A vibration sensor measures the amount and frequency of vibration in a machine or equipment. Those measurements can help detect imbalances and other issues to predict maintenance needs. Additionally, a vibration base measurement can provide a machine signature for good parts and a healthy machine. • A flow meter can be added to a device to track whether it is applying the necessary amount of lubricant to the material, which can impact product quality. Capturing sensor data in software Data from sensors is captured by a programmable logic controller (PLC) or a data logger. The device can then convert the data to a usable computer format and make it accessible to the shop floor network. Newer smart IoT sensors can be made directly available to the shop floor network without intermediary devices. Once accessible to the network, the information is usually sent to a server that supports the Open Platform Communications (OPC) standard for industrial communications. The OPC or other software may be needed to calibrate the data to match a machine’s own values. From there, the information can be fed into a manufacturer’s enterprise resource planning (ERP) and/or manufacturing execution system (MES) software to populate various real-time reports with the data. Both current and historical data are maintained in the software, making it possible to analyse this information from the perspective of quality, efficiency and other key metrics. Manufacturers typically use data captured by the software to: • Collect information for end-of-shift reporting to help determine if the material is equal to the number of parts that the team anticipates producing. • Track counts in a work centre to assist in production planning. • Match the work order to what’s running in the machine to update inventory consumption. • Compare how many cycles have been completed versus parts made to understand the scrap being produced. • Determine downtimes for each work centre. • Look for out-of-limit processes for quality control. Harnessing real-time monitoring The most powerful use of sensors comes from combining the real-time data they generate with real-time production and process monitoring functionality that is integrated with the MES and ERP systems. Real-time production monitoring helps bring meaning to the counts from sensors by capturing production cycles that can take mere milliseconds and displaying averages, such as X amount of product per minute. Counts in ERP and MES software also support automated workflows, such as materials orders, inventory updates, production scheduling, and other shop floor and accounting processes. When combined with statistical analysis, real-time production and process monitoring can help establish parameters for performance, wear, etc., as well as track and flag when production cycles and processes measured by machine sensors head outside an acceptable Roadmap to IoT Success with legacy manufacturing equipment
Focus on: Maintenance 4.0 Maintenance Matters October/November 2024 www.pwemag.co.uk Plant & Works Engineering | 13 range. The data can be used by an MES for scheduling production, ensuring quality, and performing preventative maintenance, among other processes. The metrics or key performance indicators (KPIs) tracked will be specific to each manufacturer’s priorities. But starting with too many KPIs can ground monitoring and analysis initiatives to a halt— defocusing efforts while consuming valuable staff time. So, management should prioritize creating a short list of KPIs most relevant to the business. Once the company is regularly tracking metrics against these KPIs, new KPIs can be added. Getting started To get started, the most successful manufacturers get sensors and monitoring working on one machine and begin collecting the sample information everyone agrees is important to that machine. Once the data coming in looks the way the team wants it to, the approach can be applied incrementally to other machinery. It’s better to start with a machine where the team understands how the interface works and can be successful. Even if getting up and running is easy, the team will still learn things through the process, and that knowledge will help with the rest of the installation and give everyone confidence that the results are going to be as expected. Manufacturers also should first hook up sensors and monitoring to a well-performing machine from which the team can collect data and create a baseline of understanding. This will serve as a springboard against which to measure other machines. And, when first monitoring the data from sensors, it’s important to note that sensors placed on different parts of a machine will often produce different results—even if the type of sensor is the same. Additionally, there are physical implementation factors to consider. Many successful manufacturers have relied on their in-house maintenance teams for the install instead of using outside electricians, since the installers need to be familiar with their equipment, machines and the building. Also, because the amount of metal on shop floors can leave WiFi and wireless devices unreliable, consider using wired connections to each machine rather than wireless ones. Finally, plan for the future by having network drops on every machine. This will ensure that all machines have network capacity as the team expands the installation of sensors across the shop floor and begins to collect data. By following these best practices for bringing sensors and realtime monitoring to existing machinery, manufacturers can quickly gain insights to improve their efficiency and correct issues that have been losing money. And longer term, this can translate into greater efficiency, productivity and profitability. For further information please visit: https://www.3ds.com/products/delmia/delmiaworks NI G OD Y N B I G NRAEL SOLUTIONS TRAINING AL TECHNIC 634 731 470 ining@zen.co.uk s.co.uk ingsolutions.co. 01634 tech.training technicaltrainingsol Industry since 1980 Mechanical Practical Skills Training for ain Providing Electrical, Instrumentation & Lynn Loughmiller, Software Engineering Manager at DELMIAWorks
Maintenance Matters Focus on: Condition Monitoring 14 | Plant & Works Engineering www.pwemag.co.uk October/November 2024 Monitoring the amount of water vapour in the air, humidity sensors are essential to ensuring optimal environmental conditions for a range of industries, from manufacturing to agriculture and facility management. Ross Turnbull, Director of Business Development and Product Engineering at custom IC design and supply specialist, Swindon Silicon Systems, explains how humidity sensors keep the air clean and ensure an optimal industrial environment. Despite their niche, humidity sensors are more common than you may think. In manufacturing and warehousing, maintaining humidity levels is crucial for the quality and longevity of products, especially in sectors like pharmaceuticals, food processing and electronics manufacturing. Humidity sensors help monitor and control environmental conditions, preventing damage to sensitive materials. In HVAC systems, humidity sensors ensure comfortable and healthy indoor air quality by adjusting humidity levels to the desired set points. Elsewhere, in agriculture, they’re used to monitor soil moisture and ambient humidity, enabling data-driven irrigation practices that offer optimised water usage, improved crop yields and reduced waste. Exploring sensor types Humidity sensors, also known as hygrometers, measure the amount of water vapour in the air. These sensors typically operate based on one of three main technologies: capacitive, resistive or thermal conductivity. Capacitive sensors use a hygroscopic dielectric material placed between two electrodes. As the humidity changes, the dielectric constant of the material changes, altering the capacitance. This change is measured and converted into a humidity reading. Capacitive sensors are highly accurate and have a fast response time. They are also less affected by temperature changes, making them suitable for a wide range of applications. Their stability and long-term reliability make them a preferred choice in many industrial settings. Resistive sensors measure changes in electrical resistance as humidity varies. A hygroscopic material's resistance decreases with increased moisture absorption, allowing for humidity measurement. These sensors are typically more cost-effective than capacitive sensors and are simple to produce. They are durable and perform well in harsh environments, which makes them suitable for outdoor applications and industries where conditions can be challenging. Thermal conductivity sensors measure the change in thermal conductivity of the air due to humidity. They typically have two thermistors — one exposed to the air and one isolated. The difference in their readings is used to calculate humidity levels. Thermal conductivity sensors are particularly useful in applications where high accuracy is required over a wide range of humidity levels. They are also less susceptible to contamination, which makes them ideal for environments where the air might contain dust or other particulates. Taking action Thanks to the digitisation of sensing technology, it’s possible to use the data collected by humidity sensors to generate real-time insights into environmental conditions, so that appropriate changes can be made to control the moisture in the air and ensure conditions remain optimal. To unlock this insight, it’s essential to convert the analogue values generated by the humidity sensors into a digital format. While this can be achieved using numerous off-theshelf integrated circuits (ICs), for optimised sensor performance, an Application Specific Integrated Circuit (ASIC) is the better choice. ASICs are ICs that are tailored for specific applications, offering numerous advantages over general-purpose integrated circuits (ICs). They are designed to meet specific performance criteria, which ensures that the humidity sensor operates within the desired parameters, enhancing accuracy and reliability. One of the most attractive benefits of an ASIC is its improved performance. Complete optimisation of the chip’s design means that additional redundant components are removed, allowing more power to be invested in areas where it matters. Freedom in design means that the ASIC can be designed to interface directly with the humidity sensor to provide sensor-specific conditioning. This optimised performance makes the sensor’s insights ultrareliable, which is particularly important for applications where a change in humidity could have huge consequences on operational efficiency. An ASIC also offers the significant advantage of obsolescence protection. Standard ICs may be discontinued at any time, potentially leaving manufacturers with a limited stock that will ultimately need to be replaced, and may even require a redesign. Swindon Silicon offers a comprehensive nonobsolescence plan as part of its design and manufacturing process. If a product is designed to last 15 years in production, then Swindon will select a suitable silicon process with the required maturity and longevity. Humidity sensors are essential to keeping the environment optimal —without them, there’s a risk to the performance of equipment, quality of products and the protection of sensitive materials. Designing a system with ASICs takes the reliability and accuracy of the data up a notch, to ensure environmental stability and better, faster insights if humidity does rise above the threshold. For further information please visit: https://www.swindonsilicon.com The role of humidity sensors in maintaining optimal conditions
Turck Banner Ltd. Blenheim House, Blenheim Court, Wickford, Essex SS11 8YT Tel: 01268 578888 wireless@turckbanner.co.uk Wireless Vibration & Temperature Monitoring As simple as your check engine light Distribute Connected data solutions • Data is pulled from the controller via cellular or Ethernet and Stored in a SCADA or Cloud Platform Alert and Consumption Consume the data via Dashboards, alerts and long term analysis • Early detection of any increase allows for planned, preventative maintenance Measure & Collect Wireless Vibration, Temperature & Current Monitoring • IP67 & IP69K Sensors • Sensors Powered by batteries Transmit IIOT Gateway/Controller Solution Kits • Sensors send data wirelessly to Gateway/Controller • Machine Learning Algorithm
Maintenance Matters Problem Solver 16 | Plant & Works Engineering www.pwemag.co.uk October/November 2024 As renewable energy facilities upgrade, mitigating harmonic noise is essential for reliable operation. A leading control systems supplier partnered with CP Automation to address this challenge, implementing active harmonic filters and uninterruptible power supply systems. This collaboration aimed to enhance power quality, prolong equipment lifespan, and safeguard continuous energy flow. PWE reports. The UK-based plant was planning a major upgrade and issued a tender, which was won by a well-known control systems supplier. As part of the upgrade, the control systems supplier needed to minimise harmonic noise on site and ensure a reliable back-up power supply. The supplier knew that power quality was an important factor, but it lacked the expertise in this area. At this point, it approached CP Automation. The problem with power Harmonic noise is a pressing challenge in many industrial facilities that contain non-linear loads. Power plants typically include variable speed drives (VSDs) to control motor speed and transformers — a common source of harmonic distortion. Though critical for keeping industrial machinery running, VSDs can introduce harmonics due to the rapid switch of power electronic components like Insulated-Gate Bipolar Transistors (IGBTs). If the total harmonic current distortion (THDI) of the VSDs increases significantly and passes back to the transformer, this can cause problems. All the different loads sum at the transformer with current distortion and if they exceed normal levels, they can breach the harmonic loss factor (FHL) curve, and the transformer will start distorting the waveform it sends out to surrounding electrical equipment. As well as derating the available power from the transformer, the distorted voltage waveform that follows will degrade the hardware receiving that signal in the power network. This can damage the components inside and shorten the devices’ life expectancy by several years. Clean, continuous power Every project has its unknowns but, in this case, CP Automation had a solution designed to specification. It supplied six Comsys ADF P300 active harmonic filters, which help clean up the total harmonic distortion (THDI) of the current caused by VSDs. “The filters actively inject a counter signal to cancel out the harmonic noise returning to the transformer, acting like noisecancelling headphones,” explained John Mitchell, global sales and marketing director at CP Automation. “We supplied six of these filters across the site.” Meanwhile, CP Automation helped ensure a back-up system was in place so that essential services would continue in the event of a mains outage. It did this by supplying two uninterruptible power supply (UPS) units, which can provide almost instantaneous power for critical services, like fuel handling and conveyer systems and boiler control units. Crucially, it also specified Ixon IoT routers to improve site connectivity and enable remote monitoring. Therefore, if an outage or a power quality event was detected, CP Automation’s team could dial in and provide remote support. With the Comsys filters and UPS systems now in place, the control systems supplier could complete the upgrade, and the plant would be protected from unexpected power issues. Not only would this boost uptime, but it would also help reduce long-term costs by prolonging the lifespan of the electrical equipment on site — protecting them from the effects of waveform distortion. “Like other power plants and industrial facilities, the installation of harmonic filtration has opened the door for subsequent monitoring capabilities,” added Mitchell. “Analysing options include portable clamps such as multimeters and fixed power quality meters, such as Powerside’s PQube 3 and Janitza’s range of panel mounting and din rail analysers.” By strategically placing these power quality meters across plants, engineers can track long-term trends and carry out root-cause analysis. Meanwhile, conducting a power quality survey can help them gain a snapshot of what the plant looks like and identify any ongoing issues. For further information please visit: https://www.cpaltd.net Safeguarding renewable energy with power quality
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