Drives & Controls April 2023


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50 CONTENTS n Drives & Controls is a controlled circulation publication. If you live in the UK and want to subscribe phone 0333 577 0801 or fax 0845 604 2327. Alternatively for both UK and overseas subscriptions please subscribe online at If you have any enquiries regarding your subscription, please use these numbers. 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. Paid subscriptions UK: £110 per annum Europe: £145 per annum Rest of World: £180 per annum Printing: Warners Midlands PLC., PE10 9PH ISSN 0950 5490 Copyright: DFA Media Group 2023 NEXT ISSUE The May issue of Drives & Controls will contain our annual supplement on electric motors, plus a look at developments in linear motion technologies, and applications in the scientific, pharmaceutical and medical engineering markets. UPDATE 25 Comment 26 ABB Back to Basics 58 Gambica Column 61 New Products 64 Design Data and Multimedia 64 Appointments 65 Products & Services IN DEPTH Follow us on Twitter @DrivesnControls Drives Magazine Web site Follow us on LinkedIn @ Drives & Controls Join us on Facebook Drives & Controls Drives& Controls REGULARS DfAmedia group 40 34 30 8 5 62 DRIVES & CONTROLS April 2023 Vol 39 No 4 Editor Tony Sacks t: 01732 465367 e: Consultant Editor Andy Pye t: 07808 137312 e: Production Manager Sarah Blake t: 01233 770781 e: Operations Manager Emma Floyd t: 01732 370340 e: Marketing Executive Hope Jepson t: 01732 370340 e: Financial Finance Department t: 01732 370340 e: ADVERTISING Sales Director Damien Oxlee t: 01732 370342 m: 07951 103754 e: Sales Manager Andy Wylie t: 01732 370341 m: 07939 607855 e: DFA Direct Ian Atkinson t: 01732 370340 e: Italy Oliver & Diego Casiraghi e: t: +39 031 261407 f: +39 031 261380 Managing Director Ryan Fuller t: 01732 370344 e: Chief Executive Officer Ian Atkinson t: 01732 370346 e: Reader/Circulation Enquiries Perception-MPS Ltd t: 01825 701520 e: HEAD OFFICE DFA Media Group 192 High Street, Tonbridge, Kent TN9 1BE t: 01732 370340 f: 01732 360034 e: 46 5 News A round-up of the latest business and industry developments from around the world. 30 Technology Cutting-edge innovations in motion, power transmission, controls and related technologies. 13 Talking Industry Live In a special 12-page preview we look forward to what visitors to this month’s free Talking Industry Live event at the National Manufacturing Centre in Coventry, can expect to see and hear. 40 Machine Vision Examples from the wide range of applications emerging for machine vision technologies, including tracking batches of laundry and the automated processing of apples. We also examine trends in the vision sector, and offer advice on choosing machine vision lighting systems. 46 Conveyors and Materials-Handling Advice on ensuing that conveyor belts in food-processing plants are operating hygienically. We also examine the use of linear-motor-driven production transport systems as a flexible alternative to traditional belt conveyors for some applications. 50 Machine-Building We look at the technology involved in a UK-developed low-cost automated medical diagnostics system that could affect the way that medicine is practiced worldwide. Plus an expert offers advice on identifying and assessing fire risks in machinery. 56 Talking Industry The latest in the series of Talking Industry online panel discussions considered the role that manufacturers can play in decarbonisation and cutting energy consumption. We report on a lively discussion that took many turns. 53 50 58

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NEWS n 5 Custom gearboxes will ‘revolutionise’ the transmission market THE GERMAN GEARBOX-MAKER Flender has announced a new generation of single-stage helical gearboxes that, it predicts, will revolutionise the market. The company – previously owned by Siemens, which sold it to the investment firm Carlyle in 2020 – says that the new Flender One gearbox sets new benchmarks for efficiency, operating costs, ease of ordering and maintenance, with every box having onboard monitoring and analysis to help avoid failures. The new gearbox is a successor to the Flender Standard Gearbox (FSG) which was launched around 30 years ago and has become an industry standard. There are more than 500,000 Flender gearboxes in operation around the world. Thanks to a redesigned housing and optimised gear set, the new generation of gearboxes will cut operating costs while making efficient use of resources. The new boxes are said to be“unique”in linking product design and digital services throughout the entire lifecycle, from ordering to operation. The new boxes, launched at this month’s Hannover Fair, will be produced to individual customer requirements. They will be designed and dimensioned precisely for each application, avoiding wastage of raw materials and resources. Flender says that the new-generation gearboxes will define a new path where “standard”is not the focus anymore. Users will be able to configure their gearboxes online with three pieces of information: the application, the power and the speed. If they want, they can add more detailed parameters. The configurator will produce a 360-degree preview of the box as well as 3D data “within seconds”. “We are offering to take the timeconsuming preliminary considerations off our customers’hands,”says Flender One project manager, Dr Jan Reimann. “We no longer ask for the specifications and features of the gear unit, but only for the desired benefits.” “Each gearbox is designed to meet individual requirements,”adds Rouven Daniel, Flender’s president for industrial gears.“The customer gets exactly what he needs – no less and, especially, no more. In addition, we simplify and accelerate all processes, including predictive service. This saves time and money and contributes to climate protection through minimal use of resources.” One way of ensuring that customers get the box they need, is that Flender has developed what it claims is the world’s narrowest gear ratio range, with 103 steps between 1 and 7.1 per size. This allows the ratio to be optimised for maximum efficiency. The deviation between the desired speed and closest available option will be 1.5% at most. “With Flender One, our customers receive a completely new type of gear unit solution, precisely tailored to their application, exactly according to their requirements and preventing waste while utilising the smallest drive concept possible,”says Flender CEO, Andreas Evertz. “The reduced energy requirement during operation also helps to protect resources.” The gearboxes have 35% larger housing surfaces than previous models. Distinctive cooling ribs increase their thermal capacity and, depending on the application, can eliminate the need for external cooling, saving energy and cutting running costs. The Metaperform gearing is also said to reduce power losses by up to half, compared with previous boxes. This is achieved through a combination of improved rolling behaviour and more uniform contact surfaces. Each gearbox will be fitted with Flender’s new AIQ monitoring and analytical technology which allows operating states to be monitored via an online portal or app. Detailed condition monitoring of individual components detects any problems at an early stage, avoiding potential failures. The monitoring capability is also said to result in reduced wear and increased availability. AIQ can be also be retrofitted to old or third-party boxes. “Flender One is a step towards a completely new customer experience in drive technology,” states Daniel. “The customer can look forward not only to a new gear unit, but also to a faster ordering process and optimised operation throughout the entire lifecycle. This is a unique gear unit solution in the market.” “What makes Flender One unique, is the ability to exactly meet customer requirements while processes automatically run in the background – over the entire lifecycle from order to operation in the plant,”adds Flender CEO, Andreas Evertz. “The fully digitalised engineering process is a further milestone. Automatically designing parts according to customer requirements without human interaction. This is the future of the industry.” Flender promises that there are “further developments to follow”and is also applying the AIQ technology to its couplings portfolio. April 2023 Flender predicts that its new generation of single-stage helical gearboxes will revolutionise the market. The AIQ monitoring and analytical technology (shown below) predicts potential failures.

A DIGITAL PLATFORM has been set up with up to £6m of Government backing, to help connect the UK’s PEMD (power electronics, machines and drives) community and to close the skills gap in the sector. A recent conference to launch the Electric Revolution Skills Hub, was told that if action is taken now, the UK could become a PEMD hotbed, generating more than £12bn of revenue by 2025. Hundreds of thousands of new skilled jobs will need to be created over the next two years to reach this goal. The Hub – offering access to training, development and jobs – has been developed by Coventry University in collaboration with UKRI (UK Research and Innovation) and its Driving the Electric Revolution initiative. It will be underpinned by a “body of knowledge” mapping the skills and technologies needed. Jaguar Land Rover, Lotus, maxon and many SMEs are already backing the initiative, with 150 companies and organisations set to benefit in its first year. “The Skills Hub is a dedicated platform created to benefit the sectors that make up UK PEMD,” explains Deepak Farmah, the Hub’s commercial director. “We’ve allowed too many sectors disappear or become design houses, letting other countries manufacture our technologies – we can’t let this happen to electrification and clean mobility. “The opportunity is huge, and we’ve got some of the brightest minds in the industry,” he adds. “Now is the time to seriously look at capacity and capability, ensuring we have the people in place – with the right skills – to take advantage of the emerging demand for PEMD. “You will be able to find training courses through a trusted directory, as well as sourcing new talent through an interactive jobs board [thought to be the first for the PEMD sector]. The platform will also be a vital resource for people looking to make the transition into electrification.” The Hub plans to develop a common language for the PEMD sector to bring clarity to the way businesses, training providers and individuals talk about the topic. “Not only is the Hub creating a complete body of knowledge, it is also providing the availability to upskill and re-train engineers,” says Driving the Electric Revolution’s deputy director, Venn Chesterton. Electrification will be essential if the UK is to achieve its goal of net-zero greenhouse gas emissions by 2050. However, the skills gap could be a major obstacle to reaching this goal. Research by the High Value Manufacturing Catapult, the University of Warwick and the Faraday Institution has found that 70,000 new employees will be needed for the UK’s electric automotive industry over the coming decade, while the energy sector will need to replace or retrain 48% of its workforce – a total of 277,000 employees. While the Skills Hub is focusing on training and careers, Driving the Electric Revolution has also launched four industrialisation centres around the UK with more than 35 partners. These centres help businesses to develop and scaleup new PEMD technologies and manufacturing processes using world-class technologies. The initiative has an £80m budget for the period 2019-2024. There is a video about the Hub on YouTube: n NEWS April 2023 6 New skills hub could help to boost the UK PEMD sector to £12bn p Rockwell Automation has bought Knowledge Lens, an Indian company that combines digital technologies with deep data science, AI (artificial intelligence) and engineering expertise to provide insights from enterprise data. The Bengaluru-based business will join Kalypso, Rockwell’s digital services business, to help manufacturers around the world to accelerate their digital transformations. Details of the transaction have not been revealed. p Schaeffler is buying the French condition-monitoring specialist EcoAdapt SAS to strengthen its position in the field of digital predictive maintenance, and to expand its industrial portfolio. The terms of the deal have not been released. EcoAdapt combines smart hardware and data analytics to analyse and optimise energy consumption, and to offer predictive maintenance for electrical rotating machines by analysing their electrical signals. p Variohm has acquired the US magnetic switch and sensor manufacturer, Magnasphere. Its product range is based on a patented magnetic switch technology said to offer advantages over reed, Hall Effect and other types of switch in terms of its failsafe security, EMI resistance, installation simplicity and cost. p ABB is investing $20m to boost production at its North American robotics headquarters in Michigan. The highly automated facility will include AI-enabled robots, digital manufacturing using modular production cells, and autonomous mobile robots. The expansion will add 72 skilled jobs to the 300 already employed at the site. p The Manufacturing Technology Centre is opening an advanced manufacturing training centre at its Liverpool facility which will deliver skills to businesses and learners in the North West. The centre will offer upskilling courses and HNC programmes, as well as a new oneyear Level 2 Lean Manufacturing Operative apprenticeship covering topics such as production, quality control, and health and safety. p The UK compressed air and fluid power specialist Thorite has launched a campaign to raise awareness about unseen energy inefficiencies in compressed air systems that can lead to high costs. The Behind Closed Doors campaign urges users to monitor what is happening in their compressor houses, where leaks that go unnoticed can inflate energy bills. NEWS BRIEFS The Electric Revolution Skills Hub will offer access to training, development and jobs

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April 2023 8 BMW HAS STARTED to “operate” a new plant virtually, more than two years before the real factory begins production. In what it calls a “revolution in factory planning,” virtual manufacturing is already underway for its Debrecen factory in Hungary, which is due to start producing BMW’s next generation of allelectric models, the Neue Klasse, in 2025. The factory will be BMW’s first facility to be planned and validated completely virtually. The company is using Nvidia’s Omniverse Enterprise industrial metaverse platform to run real-time 3D digital twin simulations to help optimise the factory’s layout, robotics and logistics systems. The platform allows manufacturers to plan and optimise factory projects entirely virtually, and to enter production faster and operate more efficiently, improving time-to-market and sustainability. It will help them to reduce risks, and to ensure that new plants will operate successfully, before committing to massive construction projects and capital expenditures. BMW regards the virtual planning approach as a blueprint for future planning processes in the group. It plans to extend these capabilities to its sites around the world. “Virtualisation and artificial intelligence are accelerating and refining our planning,” explains Milan Nedeljković, BMW’s board member for production. “With the various planning systems consolidated within a digital twin, our teams around the world can now work together in real-time and make decisions faster and on a more solid foundation. This makes us much quicker and more efficient and saves on costs as well.” The Neue Klasse vehicles, based on a new architecture, will mark a fundamental transformation to BMW’s iFactory concept, which Nedeljković describes as “our masterplan for the automotive production of tomorrow”. This transformation started in in 2020, when BMW started to 3D-scan all of its vehicle and engine plants. Since then, it has scanned more than 7,000,000m2 of indoor and 15,000,000m2 of outdoor production spaces. Any subsequent modifications can be integrated digitally with a re-scan, ensuring the data is always up-to-date. Virtual planning is now under way for the 1.4km2 production hall at Debrecen. The Omniverse platform is allowing production experts to use live data both in-house and with suppliers for detailed planning and to optimise the processes and individual systems for the plant. Structure and facility data can be integrated with equipment and assembly line data. In future, items and part numbers for production materials will be available as well. Alternative layout options – for robots in work cells, for example, or for logistics areas – can be viewed as real-time, photorealistic simulations, and changed as required. Any modifications can be evaluated, validated and implemented in real-time. BMW’s suppliers can be involved in the decision-making. For example, the technology can be used to explore the possibility of adding a robot in a location where floor space is limited. It can solve the problem on the fly, with logistics and production planners able to visualise and decide the ideal placement for the robot. “This is transformative – we can design, build and test completely in a virtual world,” says Nedeljković. Later, product, process, quality and cost data will be available in the Omniverse platform, alongside the development, planning and production processes. Other additions are expected to include “invisible” processes such as the consumption of energy and resources. The platform will enhance digital operations as well – a crucial stage that BMW and Nvidia teams are already tackling. Also in the future, it will be possible to localise operational faults in seconds to minimise downtime. “Digitalisation is moving fastest in the automotive industry and BMW has been a leader in advancing this vision,” says Nvidia’s founder and CEO, Jensen Huang. “We are partnering closely with BMW, using Nvidia Omniverse to help streamline their manufacturing processes, enhance collaboration and further efficiency. Our collaboration will continue to push the frontiers of virtual integration for the next generation of smart, connected factories around the world.” BMW runs new plant virtually, two years before production starts n NEWS BMW is already running its new Debrecen plant virtually more than two years before it is due to enter production Hannover Messe 17–21 April, 2023 Hannover, Germany The industrial megashow is expected to attract around 4,000 exhibitors with the theme for 2023 being Industrial Transformation – Making a Difference, and the partner country being Indonesia. The event will be broken down into seven areas including: Automation, Motion and Drives; Digital Ecosystems; Energy Solutions; Engineered Parts & Solutions; Future Hub; Compressed Air & Vacuum; and Global Business & Markets. Talking Industry Live 25 April, 2023 MTC, Coventry A free-to-attend one-day event organised by Talking Industry in partnership with the Manufacturing Technology Centre. The event will include a series of panel discussions, workshops, seminars and an exhibition. Topics being discussed include robotics, automation, digital manufacturing and AI. Attendees will also be offered tours of the MTC, as well as complimentary breakfast and lunch. Robotics and Automation – A New Perspective 2023 10-11 May, 2023 MTC, Coventry A free two-day conference which will explore the future of automation in the UK and demonstrate the opportunities available to UK industry. Topics will include barriers to adoption, opportunities for robotics in skills development, and how to tackle the challenges presented by automation. Technologies being covered include AI, machine vision, sensing, cobots and mobile robots. Manufacturing & Engineering Week 2023 7–8 June, 2023 NEC, Birmingham The event will bring together live and digital events including the Design & Engineering Expo 2023, the Smart Factory Expo (which replaces the earlier Manufacturing Expo) and Maintec, as well as a zone dedicated to the Drives & Controls, AirTech and Fluid Power & Systems shows that the organiser, Nineteen Group, acquired from DFA Media. Another acquisition, The Hennick Group, will bring the SME Growth Summit, the Sustainable Manufacturing Digitalisation Summit and the Manufacturing Top 100 Awards. Automation UK / MVC 20-21 June, 2023 CBS Arena, Coventry Automation UK is a new annual exhibition championing the use and development of automation and industrial robots in UK industry. Organised by Bara (the British Automation and Robot Association), it will run alongside the existing Machine Vision Conference (MVC) and exhibition, organised by Ukiva (the UK Industrial Vision Association). Bara and Ukiva are both part of the PPMA (Processing and Packaging Machinery Association).

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n NEWS April 2023 10 ABB HAS LAUNCHED an initiative to encourage users to specify higher-efficiency large motors by guaranteeing to refund operating costs if the machines do not meet promised efficiency criteria. The Top Industrial Efficiency (Tie) scheme is an attempt by the motor-maker to overcome the tendency to specify the lowest-cost machine that meets an application’s specifications. This is a particular problem with motors that are specified by OEMs (original equipment manufacturers) who will not have to pay the motor’s running costs and therefore often specify the lowest-cost option rather than the most efficient. ABB wants OEMs to offer their customers a choice between the highest-efficiency options and the lowest-cost motors that will meet their specifications. It says that the Tie option will offer the same performance, ease of use and reliability as the lower-cost alternatives. Motors that meet the Tie criteria will be more expensive because they need more copper, use higher quality electrical steels and require new tools to produce optimised stator geometries. One problem in promoting high-efficiency large motors is that the mandatory MEPS (minimum efficiency performance standards) schemes for smaller motors do not apply to large multi-megawatt machines. ABB reckons that if the IE energy efficiency rating scheme was applied to its large machines, it could achieve the equivalent of IE7 (even though this level of efficiency is not yet defined for machines of any size, with IE4 being the highest agreed specification for smaller motors). David Bjerhag, global manager of ABB’s large motors and generators business, cites the example of a 20MW motor which, based on a 0.2% improvement in efficiency, could save $800,000 in energy costs and 3,000 tones of CO2 emissions over the course of a 20-year operating lifetime. Such a machine would achieve an average payback time of just 0.5-3 years, he says. At its Large Motors and Generators factory in Sweden, ABB has built a motor with an efficiency of 99.05% (equivalent to IE7) – compared to a typical value of 98.3% for large motors. Bjerhag says that if ABB’s existing customers opted for motors of this efficiency, they would save 1.6TWh of electricity over the motors’ operating lives, and cut CO2 emissions by 827,000 tonnes every year. This is equivalent to 6% of Sweden’s total annual CO2 emissions from electricity generation. ABB says that its aim with Tie is to offer users a cost-effective option with significant energy and economic savings, helping to incentivise the transition to more sustainable use of energy. It expects that legislation will eventually follow, mandating higher levels of efficiency for large motors. ABB hopes that the new option will raise awareness and fast-track the introduction of these standards. The Tie option is currently available for four- and six-pole synchronous motors and generators. ABB is hoping that the option will help to raise the efficiencies not just of motors, but also of generators and other equipment such as transformers, compressors, pumps and drive systems. ABB’s commitment under the Tie scheme is to guarantee the supply of “the most efficient product/system, that we currently can offer without affecting the reliability, or increasing the complexity” of the system. Should it fail to substantiate compliance with the Tie option, it says it will repay the user’s energy and CO2 costs during the first 100,000 hours of operation, “in no case exceeding the additional price paid for the purchaser for the Tie option”. “Once you have the option, I’m certain people will choose it,” says Bjerhag. ABB is hoping to persuade other suppliers of large machines to offer similar schemes. It points out that large motors are responsible for 10.4% of global electricity consumption. ABB promises refunds if highefficiency motors don’t hit targets ABB is offering the Tie option for its large motors and generators The Manufacturing Technology Centre (MTC) has appointed the former chair of Ford of Britain, Dr Graham Hoare, to succeed Dr Clive Hickman as its CEO, following Hickman’s retirement as chairman and his new role as chair of the MTC board. Hoare brings more than 35 years of industrial and commercial experience to the role, including two decades with Ford in a variety of senior roles. He was recently interim CEO of the battery-making venture Britishvolt, which has been acquired by the Australian firm, Recharge Industries. In 2018, Hoare was awarded the OBE for services to the UK motor industry. Mark Yeeles, vice-president of its Schneider Electric’s Industrial Automation business in the UK, has been appointed vicepresident of its Secure Power division in the UK and Ireland, succeeding Marc Garner, who now leads the Secure Power Division in Europe. Yeeles joined the automation business in 2015, having previously worked for ABB, Rockwell Automation and Omron. He will now work with Schneider’s data centre customers, end-users and IT channel partners. A new VP for Industrial Automation in the UK and Ireland has yet to be announced. + 44 1604 499 777 Lose your expensive downtime! Let us help you keep your profits Are your industrial electronics not working properly? UNIS Group is an international service organisation in the field of repair and sales of industrial electronics. Our technical specialists repair at component level, supported by advanced measuring and testing equipment. 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n NEWS MORE DETAILS HAVE been released about Manufacturing & Engineering Week 2023 – the week-long festival of live and digital events taking place at the NEC in June, including a two-day exhibition on 7–8 June that will be the new home of the Drives & Controls Show. As well as the exhibition there will be a free conference programme including two keynote conferences and events taking place in six Solutions Theatres. The first day will kick off with a talk from a Government official on its plans for supporting UK manufacturing. On the second day, an Opposition spokesperson will address the same subject. The conference will include a session on the future of UK manufacturing led by former Siemens UK CEO, Juergen Maier. Other sessions will look at whether robotics and automation are the answer to the skills crisis, how to protect against cyber-attacks, and how diversification can transform manufacturing businesses. There will be four centrepiece exhibitions: Design & Engineering Expo; Smart Factory Expo; Maintec; and Drives & Controls, which will be in the form of a zone this year, before returning as a full three-day exhibition in 2024. Within the show, Made Smarter’s Innovation Alley will showcase emerging technologies that are changing the landscape of manufacturing, while the Innovation Village, run by the seven High Value Manufacturing Catapult research and technology centres, will be an immersive, interactive area that will demonstrate technological advances that are transforming industry for a sustainable future. On the second day of the show, the Manufacturers of the Future programme – developed in partnership with Engineering UK, Make UK, Engineers Without Borders UK and the IMechE – will help students and apprentices taking the first steps in their careers. Injecting some fun into the week will be a Guitar Legends competition where entrants can win a 3D-printed guitar. A winner will be announced for each day of the show, and one will get the chance to play with a live band at the after-show party for visitors and exhibitors on 7 June. M&E Week will celebrate UK manufacturing and engineering C H A R T E R C O N T R O L S SIMPLIFYING IT FOR YOU MOTOR LOAD (kW) MONITORS AND TRANSDUCERS Protect Machines & Monitor Processes Digital load monitor - DIN rail mounted Digital load monitor - Panel mounted Analogue load transducers CHARTER CONTROLS For more information call 01424 850660 • Improving Your Bottom Line Simplifying Your Purchasing Experience Comprehensive UK Stocks for Next Day Delivery Purchase Direct from Manufacturers Agent Tailored Services & Discount Structures M&E Week’s Innovation Alley will showcase emerging technologies

On behalf of the whole team at Talking Industry Live, I would like to extend the warmest of welcomes to all delegates, exhibitors, partners and sponsors. This unique one-day event will allow visitors to tailor their own experience to be able to learn new skills, meet new suppliers and gain knowledge while networking with peers. Talking Industry Live will provide an environment for delegates to learn about cutting edge technologies and best practice through unscripted panel discussions, presentations, live demos and workshops with a focus on Robotics & Automation; Increasing Overall Equipment Effectiveness (OEE), Digital Manufacturing, and Industrial Data & AI. TI Live will show how greater collaboration and connectivity between different parts of the manufacturing process can be achieved. With digital technologies, manufacturers can connect their equipment, supply chains, and even their customers in ways that were previously impossible. This can help them to respond more quickly to changes in demand, optimise their supply chains, and deliver products that better meet the needs of their customers. The inaugural Talking Industry Live conference aims to help delegates embrace these digital technologies and learn about cutting edge technologies and best practice in the manufacturing, engineering and automation sectors. By doing so, manufacturers can improve their operations, increase OEE, optimise their supply chains, and create new business models and revenue streams to remain competitive in an increasingly globalised and digitised marketplace. Ultimately, digitalisation is crucial to the future of UK manufacturing and TI Live will connect you with the information and businesses to help you remain at the forefront of innovation and to ensure your business continues to grow and prosper for years to come. Completely FREE to attend event including parking, breakfast, refreshments and a two-course luncheon Breakfast from - 8.30 Lunch from - 12.30

The inaugural Talking Industry LIVE keynote address will be an interactive, engaging and informal podcast style discussion by Mike Hague-Morgan, Executive Director of Autocraft Solutions Group, and Dr Megan Ronayne, Head of Industrial Technologies & Manufacturing at Innovate UK KTN. Together they will explore how one of Europe’s leading OEM partners for the manufacture, remanufacture and assembly of IC engines and EV batteries transitioned from being a very traditional manufacturer using hand tools and a paper system, to a high-technology company with world-class quality, repeatability and digital traceability which has been the catalyst for such rapid growth. Innovate UK’s innovation ecosystem, including Innovate UK KTN and the Catapult Network played a vital role in the digital journey of Autocraft Solutions Group. Mike and Megan will explore how Innovate UK provided this leading powertrain manufacturing partner with collaboration, funding, and vision to give a practical and real life insight into how companies can achieve similar transitions. The discussion will move on to look at how you can grow your business, through technology adoption and implementation. They will explore the current understanding of digital processes for manufacturers in the UK, the opportunities available via funding, knowledge and innovation networks, and explain the dynamic benefits to your business including quality, productivity and upskilling improvements. Dr Megan Ronayne Head of Industrial Technologies Mike Hague-Morgan Exceutive Director

Robotics and automated systems will form a critical part of the future UK manufacturing economy. As the ninth largest manufacturing economy in the world, the UK languishes as the 27th largest adopter of robotics. Brexit and COVID-19 have exposed weaknesses in our supply chains. Industry is facing the tightest labour market we have seen in modern times. These challenges could be addressed, in part, by faster adoption of robotics and automation. How can we accelerate this adoption and develop a competitive UK manufacturing sector? Key to this transformation is creating an environment where the skills of both today and tomorrow can be developed, creating an ecosystem of high-tech businesses capable of deploying complex systems. Additionally, we must enable businesses to make strategic investments through innovative finance arrangements, maximising flexibility and reducing risk. But as manufacturing facilities do get faster and more automated, there are greater challenges, not least the safety aspects of plant and equipment. OEE (Overall Equipment Effectiveness) is the gold standard for measuring manufacturing productivity. Simply put, it identifies the percentage of manufacturing time that is truly productive. But worryingly, most UK manufacturers are running below a score of 60% and almost half are scoring under 40%. In most cases. OEE can be easily improved through straightforward measures. All aspects of machine operation contribute to OEE, including the often-overlooked human aspect. Everyone is busy, and the problem with being too busy is a complacency towards everyday issues. Focus becomes directed only to visible issues causing downtime to plant and machinery. But what about hidden downtime, that mounts up and causes cycle times to drift? 10.30 - 11.15 AUDITORIUM 11.15 - 12.15 AUDITORIUM

Using data to focus on the right issues will help drive OEE leading to the optimisation of the facilities performance, resulting in greater productivity and a more sustainable manufacturing footprint. How to interpret and visualise existing data and unlock new data? When it comes to setting out on a digitalisation initiative or a smart factory project, it is important to start with a strategy in place and a pivotal part of that strategy should be to define what we want to achieve. Artificial intelligence and machine learning offer opportunities for increasing business performance, agility, and growth. Business leaders are determining how these techniques can integrate successfully with human intelligence and what they will deliver as they evolve. Despite this, there are questions regarding the ease of implementation, adoption, operation, and trust associated with these types of technologies. What is the current state of artificial intelligence in manufacturing, the challenges and barriers to adoption? What opportunities are offered for manufacturing, to the national net-zero goal? In order to adopt AI successfully, a companywide strategic approach is required, but its widespread adoption is hampered by a lack of a suitable machine learning infrastructure and the need to centralise data. These in turn lead to high costs, privacy risks, and overdependency on cloud platforms and network availability. 14.00 - 15.15 AUDITORIUM

Although the number of machinery-led workplace accidents has fallen over the past few years many experts are expecting this figure to rise as advanced technology is introduced onto the factory floor. With some of the most advanced machinerysafety technology available - Euchner is in a great place to explain the emerging trends in safety-related control standards and what this means for your business. Additionally, each of the workshop sessions will include a Q&A discussion with practical contributions from industry leading experts in the field of industrial cyber-security and machinery safety integration. This informative and interactive legislation-led plant-safety & cyber security focused workshop gives everyday advice and promises to be insightful for those organisations starting their journey or already well on their way. layer of safety & security into the mix then careful consideration is required. If the office document takes a few-hundred extra milliseconds to get to the printer then this is not a big deal but if this is an emergency stop command shutting down a hazardous process the consequences of those few hundred milliseconds could be damaging. A great presentation covering safety over digital platforms is promised. COBOTS still need consideration – COllaborative roBOT deployment is growing exponentially and across a diverse range of applications… although these systems regularly have a level of inbuilt safety control within, too often the integration does not consider the wider risks involved when installing this type of equipment. Machinery Safety Standards & Legislation – From UKCA to the latest developments in Safety-Related Control System Standards, the workshop will offer practical advice and assistance to demystify the complex framework currently in place. Experts will deep dive into a number of too-often-neglected topics including ownership of the safety-related IP, the missing steps in the Risk-Assessment process and the current trends including IO-Link Safety. Some of the topics covered: OT (Operational Technology) v. IT (Information Technology) – the increased use of Ethernet based fieldbus systems throughout our factories brings with it a need for a different skillset and when you add the additional

Skills shortages are apparent at all levels, however, after listening to our customers this is particularly an issue in highly skilled areas such as panel design, manufacturing and wiring. With this in mind, companies are turning to technology to help them work smarter and close the skills gap within industry. Join engineers from EPLAN and Rittal for the ‘Smarter Working’ workshop to discover new solutions and applications to make your electrical design, component mounting, and wiring easier and faster! Throughout the workshop our skilled engineers will be showcasing the following:  From the connection point to the exact wire routing, discover how the webbased application, EPLAN Smart Wiring, provides technicians with step-bystep instructions needed to easily and successfully wire a control panel.  Explore how EPLAN Smart Mounting simplifies the manual installation of mechanical & electrotechnical components through clear digital instructions that can be accessed via a tablet or computer. The purpose of the workshop is to highlight how the continuity of data from a single source of truth streamlines panel building. Data can seamlessly flow from electrical engineering design, through to panel modification and wire fabrication, and finally to the technicians constructing and wiring the panel using digital applications. You’ll also get the opportunity to test such solutions within a Rittal AX enclosure to see just how easy mounting components and wiring a panel can be! *parked towards the rear fo the venue ask a RITTAL/EPLAN team member for a tour!

Where to start, what are the gains and what is the ROI? Being a specialist for automation technology with 50 years of experience in industrial manufacturing ifm is your reliable partner for the introduction and implementation of tailor-made digitisation solutions on the way to the smart factory. 3D printing is now considered a standard part of manufacturers toolkits across industry as a cost effective and accelerated alternative to conventional manufacturing techniques, such as subtractive manufacturing. Robotics & automation can enable a broad adoption of 3D printing, the key to which has to be ease of use and repeatable outcomes within fully integrated highquality systems. How do we create an environment where both our current and future workforces can work harmoniously to achieve maximum output? In an ever-changing society, it is important to ensure the future workforce are provided with the right tools, training, and knowledge, to maintain a competitive future industry. Nikesh will discuss how at GAMBICA they have formed their Young and University councils which aim to achieve just this and focus on key areas for the future generations such as STEM, Upskilling, Development and Sustainability. He will discuss how a trade association are able to act as the mediator in bringing together diversity in the working environment. Learn how collaborative automation can enable a more flexible production floor. In this seminar we address key barriers to adoption such as skills, cash and application development and show how technology can work in harmony with humans to optimise outcomes. Static production lines have made way for the next generation of robots, replaced by intelligent, mobile robot units, that can navigate autonomously and offer total flexibility for industrial manufacturing & internal logistics, heralding the next era of cyber-physical production landscapes. An introduction to Made Smarter. Find out who can join, the benefits and how to get the most from the programme. We will also look at what companies have joined and why. 10.30 - 11.15 11.30 - 12.15 14.00 - 15.15 ROOM 1 ROOM 2 SEMINARS

BRAINBOXES As a market leader in safety solutions for machinery, Euchner is committed to helping businesses keep their employees safe and comply with safety regulations. Our products, including safety switches, safety relays, safety sensors, and safety interlocks, are designed to ensure that machinery can operate safely and reliably, protecting employees from harm and avoiding costly downtime. Attendees will have the opportunity to explore our latest products and technologies, network with peers and industry experts, and discover new ways to optimise safety and productivity in their manufacturing operations. One of our well-respected Safety Consultants will also be available to talk to and provide support to design engineers from design stages to deployment of machinery and offer advise on how Euchner can support you through this journey. We’re excited to be a part of this important event and look forward to sharing our insights and expertise with attendees. Charter Controls is a family-run business established in 1992 and prides itself on helping its customers during these difficult times. For many years, Charter Controls has been a global sourcing agent to high-value service providers and distributors, as well as supplying directly to panel builders, importing control panel products from original OEMs who manufacture for larger established brands across the globe. Our company’s ethos of “working for our customers” has enabled us to establish many strategic partnerships, which has been key in securing year-on-year growth for the company. As an appointed manufacturers’ agent, Charter Controls has been able to differentiate itself uniquely, by offering control panel components at competitive prices, and enabling UK panel builders to reduce their product purchasing costs and eliminate long delays in project completion. Charter Controls, simplifying it for you! GAMBICA is the Trade Association for Instrumentation, Control, Automation and Laboratory Technology in the UK. Our insight and influence help our members to be more competitive by increasing their knowledge and impact. Together we remove barriers and maximise the market potential in our industry. • We form a community of members and stakeholders that shares knowledge and best practice, shapes opinion and enhances the profile of our sector • We influence policy, standards and regulation for the benefit of our industry • We publish unique market reports and forecasts, allowing members to accurately plan future strategies and budgets • We help members develop business by promoting our industry through exhibitions, events, publications and media campaigns • We work with the future of industry through our Young Council and University groups to promote STEM sectors and address any skills gaps Being a specialist for automation technology with 50 years of experience in industrial manufacturing ifm is your reliable partner for the introduction and implementation of tailor-made digitisation solutions on the way to the smart factory. Sound hardware and software competence together with visionary ideas guarantee your continuous progress. From the individual sensor to an overall business solution - the ifm solutions are scalable so that the digitisation of your company is implemented in steps according to your wishes. Industry 4.0 is feasible – with the right partner, it is easier than you might think. ifm will accompany you on your way. Depending on your requirements, the ifm system sales will support you right from the beginning – from strategic advice, the development of individual software and hardware solutions and their corresponding implementation to advanced services. AutoLogic Systems provides advanced digital solutions and consulting to optimise manufacturing facilities and logistics. We are experts in Digital Twins and Virtual Commissioning, providing advanced 3D solutions for demonstration, simulation and controls testing. We are a Value Added Reseller of Emulate3D by Rockwell Automation. You can also optimise and automate case, pallet and vehicle/container configurations with our powerful range of software from TOPS Pro and MaxLoad Pro. With 30 years-experience providing, consulting and supporting our solutions, and now a Sonepar Company, we work with hundreds of companies across the UK to make their operations stand out from their competitors. Robots and factory automation are fundamental to the future success of UK manufacturing - many businesses are leveraging robotic automation across a wide range of tasks, for many varied reasons, which are as diverse as the solutions are available, to meet the demands of modern manufacturing methods. From industrial intralogistics and mobile, material transportation robots operating in dynamic supply chain environments to 3D printing robots, capable of measuring and optimizing processes as they print, food grade robots capable of slicing cheese or skilleting sandwiches, to medical grade robots designed and manufactured to operate precisely and consistently in the strictest of hygienic environments - the demands of automation today are that which we have never seen before. At Talking industry Live KUKA will present two new products – The KMP-600S: complete flexibility for production intralogistics, and the AMCell_: pushing boundaries in additive manufacturing – Two durable, multipurpose performers built upon flexibility and efficiency. Ai Build is a London based company providing advanced software for robotic and gantry large-format additive manufacturing systems using polymers and metals. AiSync additive manufacturing software is optimised to simplify and automate additive manufacturing from plan to print, providing reliable, repeatable results across the enterprise. Clients report AiSync AM software reducing failed builds by 65% and a 90% efficiency gain in overall build time. Advanced capabilities like real-time remote connectivity, allows clients to view, simulate, control and monitor all machines regardless of location. A digital twin provides full visual build simulation and collision avoidance. AiSync Defect Detection Capability allows quality defects to be identified in real time during the build. AiSync AM software is trusted across many critical applications including tier one automotive, aerospace, marine, energy and construction sectors. Whilst businesses around the globe are already committed to steep decarbonisation targets, gaining a clearer picture of energy as a raw material cost can accelerate sustainability drives, increase brand equity and ultimately improve your bottom line. Our custom dashboard and data collection demo uses Brainboxes hardware and open-source software to monitor energy showing how to: • Efficiently capture, aggregate and analyse your plant-wide energy data • Reduce the impact of market volatility on your production costs • Increase positive brand perception • Achieve substantial financial savings