Creating low-cost digital solutions for manufacturing SMEs

It’s a very uncertain time for everyone, and the manufacturing industry is no different. At the same time as the industry is jumping to the challenge of manufacturing critical supplies to tackle the COVID-19 crisis, many firms, especially SMEs, are having to think hard about their underlying costs, and may be looking at ways digital technologies can help them.

At the Institute for Manufacturing, our researchers are always looking at ways that manufacturers can improve and build better businesses, and how digital technologies can be used to transform factories and business models. One of our most interesting current projects is ‘Digital Manufacturing on a Shoestring’, which aims to harness low-cost commercially available technologies for mobile computing, sensing and artificial intelligence for use in small-scale manufacturing environments.

Our project lead, Professor Duncan McFarlane, explains:

‘Digital technologies promise exciting new possibilities in manufacturing. There are many opportunities for improving productivity and efficiency, both on the factory floor and in the back office. All of these improvements can help manufacturers operate more efficiently, drive down costs and strengthen customer relationships.

But there are major barriers for SME manufacturers looking to reap the benefits of digitalisation. Cost, complexity and the need for digital knowhow often make extensive digital transformation too difficult for small companies.

Most efforts in the digital manufacturing space have been focused on large-scale solutions for big companies. Such solutions typically require significant initial investment and ongoing operating costs, as well as a need for digital skills within the organisation. In addition, they may require upgrades of industrial computing and communication environments to support advanced technological solutions. Cost and disruption are high.

‘Digital Manufacturing on a Shoestring’ is an ambitious project seeking to break down these barriers for SMEs. Funded by the Engineering and Physical Sciences Research Council (EPSRC), our research team at the IfM is collaborating with researchers at the University of Nottingham and with SME manufacturers.

SMEs are looking for inexpensive and easy digital manufacturing solutions to specific problems. They typically haven’t got large specialised IT departments. So, as well as being low-cost, solutions need to be easy to use. Our aim is to enable these firms to harness the benefits of digitalisation without the excessive risk and cost of implementing systems designed for large companies.

The Shoestring project is investigating how existing and readily available digital technologies can be implemented on a low-cost basis to support growth and productivity in SMEs.’

The Shoestring approach

Helping SMEs implement digital solutions to improve productivity
Solutions must be accessible, pragmatic, useful, affordable
Based on low-cost components
Accounting for regulations, safety, security
Engaging students and local IT community
Solutions are repeatable, reusable, integrable

Examples of Shoestring solution development

Working from the priority list of solutions from the SME requirements gathering workshops, the team is already busy building solutions. Here are a few examples.

Part detection and tracking

Dr Lavindra de Silva

This solution uses QR codes to detect and keep track of parts in a factory. When parts are received from suppliers, a QR code is attached to each part and they are placed inside boxes or trays with an ID. The boxes are placed flat on a tote, which the operator then manually ‘scans’ under a webcam or low-cost camera that is connected to a Raspberry Pi and screen. The system will then identify all of the parts inside the box, scanning all of the QR codes simultaneously, and store selected information about each of the parts. The information can then be searched later, so the contents of the box can be checked. New parts can be scanned individually and matched with boxes containing similar parts.

Augmented reality status viewer

Dr Greg Hawkridge

Enabling a factory supervisor to view the status of the shop-floor systems, such as inventory management, this solution uses augmented reality on a smart phone/tablet. It can overlay status information from machines, such as stock levels, on a tablet or mobile device when the screen is held up to look at the machine. The idea is that a worker or manager can be walking down the shop floor and look at a particular machine through the app on their mobile device, and get an instant status check.

Machine monitoring

Dr Yedige Tlegenov

This solution provides a low-cost machine monitoring system that can be attached to machines, such as a 3D printer or a CNC machine, using sensors attached to Raspberry Pis and open source software libraries. It can obtain the status (such as temperature, through put, run time, etc) of the machine. Data from the sensors is sent to an open source cloud-based platform to provide monitoring information, including alerts of machine errors, and can be viewed real time on any device.

Voice assisted assembly

Dr Greg Hawkridge

This solution uses a digital voice assistant to help a worker complete an assembly task. The worker can request particular fasteners (nuts and screws) from an Alexa-enabled device which processes verbal commands. This is integrated with a turntable via a programmable logical controller. The system will provide them with the correct item and give them verbal feedback saying what the fastener or part is that’s been provided. This makes workers jobs easier and reduces errors.

You can find out more at our dedicated Digital Manufacturing on a Shoestring site.

Author

Dr David Lott, CEO of IfM Education and Consultancy Services

The views expressed are the author’s and not ICAEW’s.