A two-year Knowledge Transfer Partnership (KTP) between WMG, University of Warwick and expert industrial automation specialist Expert Technologies GroupLink opens in a new window has introduced machine learning into a range of engineering settings that were previously thought too complex to implement. KTP Associate Mateusz Ogrodnik reduced the time of designing new mechanical fixture plans* from weeks to minutes.

Challenge

Historically the job of creating mechanical fixture plans was deemed too complex to automate. Despite involving repetitive tasks, the processes were too nuanced for simple automations to handle, and tooling designers were still an essential component.

However Expert Technologies were keen to devise and implement a novel approach to this unsolved problem, so that designers’ time could be better utilised on higher value, strategic tasks in the business.

The key challenge was the sheer computational complexity of this process. A typical fixture plan has around 40 elements which would mean that around 250 parameters had to be implemented into an automated solution.

As part of this project, Expert wanted to create and embed a systematic approach to solving complex engineering problems for the future. With the use of machine learning on an upward curve, this project would pave the way for them to continue to use this kind of technology for other hugely complex problems.

Solution

With the support of WMG, they opted to apply for an Innovate UK funded Knowledge Transfer Partnership (KTP). KTPs link forward thinking businesses with a knowledge base to deliver on an innovative project led by inspired graduates.

Initially, Knowledge Transfer Associate (KTA), Cesar Reyes, was appointed. His work laid strong foundations and a year later, a second KTA, Mateusz Ogrodnik joined the team. His approach, thanks to experience in optimisation and software development, along with support from WMG's Professor Pasquale FranciosaLink opens in a new window, led to the development of a completely novel set of algorithms that reduced the computational complexity.

Mateusz arranged meetings with senior engineers at Expert to understand how an experienced designer would approach the problem which helped to speed up the time it took for the automated system to create a design. This was followed by building a prototype app, where multiple case studies could automatically be tested. As the number of bespoke algorithms grew, and time left to create a solution decreased, Mateusz spent time working directly with the engineers to undertake further beta testing to arrive at the final prototypes. Mateusz also attended the Association for the Advancement of Artificial Intelligence conference in Canada, where he was able to gather further insights for this project as well as other opportunities to take forward at Expert.

Impacts

· A final prototype tool was created which reduced the time of developing mechanical fixture plans from weeks to hours which will lead to significant cost savings for the business.

· Mateusz has been hired by Expert as a Senior Software Development Engineer.

· Expert has put new software development approaches into practice which will de-risk other software-based projects.

· The project opened up a number of ideas for other Expert employees to build, develop and share within the company.

· New software projects, including complex machine learning tasks have been brought forward and de-risked thanks to this project.

· Expert has now applied for a further Accelerated Knowledge Transfer grant to work on a similar project.

Ian Snape, Engineering Director at Expert Technologies Group said:

“To witness the ground-breaking final prototype demonstration was a realisation of an unrealistic idea four years ago. Not accepting the ‘norm’ and embracing development failure as an opportunity to dissect and optimise, is the heartbeat of this achievement. We celebrate the powerful new fusion of engineering and data science within this Expert / WMG collaboration and look forward to the next set of limitations we rip up.” 

WMG Reader and academic supervisor on this project Pasquale Franciosa said: 

“The work with Expert Technologies Group through the Knowledge Transfer Partnership root is great evidence of transferring academic research outputs into industrial operation. The project nicely bridged engineering design with digital technologies and proved that this is the way forward to support business growth, whilst releasing capacity and maximising productivity.”

For more information on working with WMG on KTP projects contact wmgsme@warwick.ac.uk

For more information on Expert Technologies Group visit:

Expert Technologies Group | Industrial Automation Technology

*A fixture is a device for locating, holding and supporting a workpiece during a manufacturing operation. Fixtures are essential elements of production processes as they are required in most automated manufacturing, inspection, and assembly operations.

“Our involvement with the Made Smarter programme gave us the confidence to move forward with one of biggest changes to the company in its 22-year history. This investment will not only allow us to improve our efficiencies but also provide us with the security to continue to grow in the future, aiding us to deliver even better products and services to our customers and ensure we remain a leader in the industry.”

Natalie Benwell, Commercial Manager, Goodflex Rubber Ltd

Warwickshire based Goodflex Rubber Ltd are world renowned manufacturers of high quality, bespoke-design silicone hoses, serving a range of industries including automotive, pharmaceutical, renewable energy, and food.

Challenge

Goodflex had plans to double their turnover over the next three years but were concerned that their Factory Management System was holding them back from achieving this growth. They had been using their current bespoke ERP system since the business was started and it had evolved over time to be used for multiple areas within the business, including material resource planning, accounts, stock management, work order management, invoicing, and delivery notes.

But they needed to move to software which would enable their day-to-day operations to be more efficient, allow them to respond more quickly to their customers and futureproof their processes.

Solution

Commercial manager Natalie Benwell got in touch with the Made Smarter West Midlands programme and was introduced to WMG’s Denis Pelych who quickly set about understanding the company’s specific requirements. It was clear that Goodflex needed an enhanced, futureproof, digital system to drive efficiencies and maintain control of some of their more complex product builds, but they were unsure what specific system to invest in.

Denis conducted a two-stage MRP and ERP* vendor selection process, with Made Smarter support and helped Goodflex select an ERP system that offered the capability they needed today, with a degree of futureproofing. The investment required was approximately £100k but Goodflex were able to access £20k with the help of a Made Smarter grant.

Natalie said:

“Denis understood and identified our needs better than we understood them ourselves and then successfully translated them into an RFP (Request for Proposal) that was such a true reflection of our business. His knowledge in the industry, not only opened our eyes to what was possible, but also took us down a route we never knew existed.”

Impacts

• The new system will help Goodflex increase the speed of response to their customers
• The new system will help Goodflex double their revenue to £10m in three years, with the potential to reach £15-20m in five years, whilst maintaining margins and investment
• The system will lead to a 20-30% efficiency improvement from the automation of business processes
• The company expect to see a 15-20% improvement in material supply and stock efficiencies
• Efficiencies gained through the system will lead to higher levels of profitability
• The new system provides better management information with the ability to set KPIs and have greater operational insight in order to make data driven business decisions
• The new system will also improve Goodflex’s business development strategy enabled by greater insight into costs and opportunities
• The new system has improved workplace motivation and will help to retain and develop highly skilled staff

*ERP vs MRP: What’s The Difference? – Forbes Advisor

Read the full story on the Made Smarter website here.Link opens in a new window

“In the last couple of months, we have almost doubled our output compared to 18-24 months ago and we can all see the benefits of the new system compared to our old processes. Our turnaround time has been reduced significantly and there are fewer mistakes to be corrected which is another bonus.”

Ben Simpson, Co-Managing Director, MyWorkwearLink opens in a new window

Challenge

Under the leadership of Managing Directors Ben Simpson and James Worthington, MyWorkwearLink opens in a new window, which was started in 1976, produces thousands of garments every week for companies large and small across the UK. Using state-of-the-art embroidery and print machines, the company adds logos, names and designs onto uniforms, workwear, teamwear, promotional items and other garments. The business also supplies PPE and non-personalised clothing from its 6,500 sq ft premises to its customers predominantly in the Midlands and nationwide.

MyWorkwear was growing rapidly and needed its internal systems to reflect the upsurge in orders.

Ben Simpson, Co-Managing Director, said: “Our systems were starting to struggle because we still had processes in place from a long time ago.”

Solution

Working with partners at Made Smarter West Midlands, colleagues at WMG undertook a digital roadmap which led MyWorkwear to buy a specialist ERP system and software that involves the embroidery machines – which embroider many garments simultaneously – ‘talking’ to a central piece of software. It also enables staff to complete the colourisation and bar code scanning on the garments.

“The comprehensive digital roadmap that we carried out for the business highlighted areas which we felt would improve their productivity. We are delighted to have played a part in improving the digitalisation of MyWorkwear which is already leading to efficiencies, and they are a great example for other West Midlands businesses to follow.”

Onur Eren, Chief Engineer, WMGLink opens in a new window

Impact

Read more here about the project and the results here.Link opens in a new window

For more information about working with WMG's SME Group email wmgsme@warwick.ac.uk