Mark Bignell

Following my last blog where I considered some of the misconceptions surrounding Industry 4.0, I want to get 'back-to-basics' and look at what the component parts of Industry 4.0 actually are. Without descending into the ‘white noise’, as described in my previous blog, it is important to have simple descriptions of what I understand big data, connected technology, connectivity, the Internet of things (IoT) and cloud computing to be: Big Data Big data is a term that describes the large volume of data – both structured and unstructured – that a business may collect on a day-to-day basis. Big data can be analysed for insights that lead to better strategic business decisions. Connected Technology, Connectivity and Internet of Things The combination of big data plus the internet is called connectivity or the Internet of things (IoT). We often control simple systems/everyday objects via computer devices by means of an app. Alternately we could combine with other control/display technologies to create a more complex system in which computers or robots make decisions instead of humans which is called artificial intelligence (AI). Cloud Computing Over the last 5 years, computing technology has evolved to enable us to collect, store and manipulate large amounts of data, usually off site in the cloud. The cloud is really a collection of large purpose-built data farms and companies pay to access their data on a pay-as-you-go basis. As you can imagine, transferring high volumes of data requires high speed internet and protection from malicious and non-malicious threats (cyber security). Sometimes these data companies or third-party companies will store whole programs tailored to specific sectors and supply them on a pay as you use basis (either per request or via licence) – this is called Software as a Service (SaaS) or Platform as a Service (PaaS). Faster internet connection has also evolved to allow this data to be transferred or accessed in almost real-time. The mobile internet has meant that this transfer can be done anywhere that there is a good internet connection (hence we have music and video streaming). Connected Technology and how it could Apply to your Business With a basic understanding of the definitions above, it’s important to next consider the real-world application to your business. There are four main areas where connected technology could have an impact: SMART Products These are ‘connected’ products – by this we mean controlled via internet/ethernet/Wi-Fi or similar. They can be simple products or include further technologies such as AI or augmented reality (AR). Do not be fooled into thinking that SMART products are complex and therefore do not apply to your business. Many simple products are using SMART technology for product registration (consumer warranty), while manufacturers can monitor the use, misuse, performance and service intervals. SMART Manufacturing If we follow the conventional manufacturing sequence from sales, design and development through to manufacturing and quality - each department depends on an input from the previous department and human intervention during the process itself. Sales departments frequently collect customer requirements, add them to a SAP system, order prototypes and answer questions regarding supply and stockists. Designers are required to optimise a product and design them on CAD – once their part in the process is complete, they then pass the design to manufacturing, who use subtractive manufacturing techniques to make the final product. Companies embracing SMART typically have customer apps where the customer can customise their order – the app can automatically link to request a sample order or SAP so parts are automatically ordered, manufacturing is then scheduled, while a CAD design is made ‘generative’ (rather than relying on designer skill) and a 3D printed prototype or similar is created. In essence, SMART Manufacturing removes many forms of waste. SMART Buildings Space comes at a premium; housing people, heating and lighting spaces alongside having the required software and IT infrastructure all comes at a price. At the same time flexible working and working from home is becoming more commonplace. What if you could understand how the space in your building is being utilised? What are the people flows? When and how are offices occupied? Can I limit the space required by buying software as a service instead of a licence hosted on your servers (i.e. pay-as-you-go)? SMART Logistics Being able to track your product seamlessly from raw parts, through manufacturing to delivery using location finding services. Skills in Demand Today We are seeing huge demand for specialists in the market, for example cloud developers, app developers, AI specialists. These people have been educated in specific disciplines, and, usually command a salary premium. To satisfy demand in lower level positions, it is quite common to take parallel skills from other industries and cross train, for example, games developers. Diversifying Skills for Tomorrow The impact Industry 4.0 will have on conventional jobs could be profound. Within a short space of time we may see additional skills move from ‘unheard of’ to ‘desirable’ and ‘mandatory’. For example, a manufacturing engineer in automation, who may have SCADA experience, may now be required to have an understanding of vision systems or a proximity location system. Or a facilities manager who, only within the last 12 months, is now expected to be proficient in specialist workspace optimisation software. It is the sheer rate of change that will catch many companies and candidates off-guard. When considering future skills, carrying out an organisational skills audit can highlight home-grown specialists and where upskilling on the latest innovations could futureproof a business. Increased automation and adoption of Industry 4.0 concepts will lead the way to a new landscape of skills and jobs. With the right planning and a pro-development culture, employees could seize the opportunity to move into fulfilling new, previously non-existent jobs, while allowing the business to move forward. What's Next? If you aren’t sure how Industry 4.0 will affect your business, then take a look at my previous blog where I outlined the benefits of utilising trade associations and the Future of British Manufacturing Initiative as starting points on your journey.

The Fourth Industrial Revolution (4IR), Industry 4.0, the smart factory and smart manufacturing – terms we hear on a regular basis that are interchangeably used to describe the advent of disruptive technologies. But what does it actually mean to your business? Is it even relevant to your business? Whenever I speak to business leaders, they have most certainly heard of this revolution, however, the raft of articles that describe the endless possibilities and warnings can soon become white noise and hype. It sounds too good to be true. Diverse and Complex And here is why. When viewed holistically, there are many facets to Industry 4.0; the topic is vast and incorporates a wide mix of technologies. Because of this, its meaning can drastically differ from business to business and person to person, indeed, even within the same organisation. Our exposure to The Fourth Industrial Revolution (4IR) as a consumer can also distort our understanding. There is an abundance of smart products and services that have filtered into the marketplace and into our daily lives; smart phones, apps, Fitbits, smart meters, smart motorways and Uber. B2C and B2B can seem like completely different worlds and leading some to believe it is more relevant to B2C businesses. Where to Start? Every business leader wants to make better products, improve productivity and gain a competitive advantage. But which disruptive technologies are relevant or beneficial to my business? How can I go about making the hypothetical a reality? What capital, time and resources are realistically required and when will I see a return? It's Good to Talk The first port of call would be to openly discuss it – speak to your customers and supply chain, trade associations, peers at events. Understand how it is affecting them – the likelihood is that you have already had some kind of contact with Industry 4.0 and may not realise it. Minor Tweaks Many manufacturers have continuously improved their processes over time; adopting advanced technology as well as utilising tried and tested methods of manufacture, often combined with lean and 6 sigma techniques. Industry 4.0 is the next improvement process and many businesses may have already begun to install sensors or have the software that, with a few minor adaptations, can analyse data in a slightly different way and be able to make more informed decisions. Trade Associations Trade associations such as Make UK, BFFF, SMMT, ADS, MIA, Rail Alliance are all aware of Industry 4.0 and each have their own bank of initiatives, data and expertise. They are there to represent you and your industry so get in touch with your account manager and find out what resources they have, which could range from improving supply chain collaboration, through to training or the mechanism to applying for funding. Future of British Manufacturing Initiative The Future of British Manufacturing Initiative (FoBMI) is a fantastic tool, free and available to all. All too often we attend events or read articles that ‘worship the problem’ rather than actually help! I would encourage any business to take the online readiness assessment tool which takes 15-20 minutes to complete. Even better, call me or one of our 4IR experts to go through the assessment with you. FoBMI is a great starting point for any businesses wanting to hone in on the areas of industry 4.0 that are relevant to their own business. The end result is a personalised report that plots how your business is doing in five key areas of competitive advantage. Listen to episode 1 of our podcast or visit our dedicated webpage to find out more.

We’ve all seen the news... the internal combustion engine is dead; the future is electric! We live in exciting times as far as automotive propulsion is concerned, it used to be that the choice was either gasoline or diesel (some limited LPG/CNG). Just a few years later and there is a much wider choice; including cryo-engines, clean 2-stroke, clean diesel, fuel-cells, hydrogen as a fuel, even compressed air engines. Some of these technologies clearly have a place in specific applications but the big investments are being made in electric vehicles. We’ve all read the news, or know someone with one, so it seems a foregone conclusion that the future is electric right? Well maybe, but it’s not that simple. Many people do not realise there is a choice of electric architecture or agree on the best path to take for the future. So let's take an armchair view of what ‘electric car’ means by exploring the different architectures competing for the pound in your pocket. Mild HybridS These vehicles have been mainstream for several years. The vehicle uses a conventionally sized internal combustion engine (ICE) but replaces the starter motor & alternator with one unit – an ISG (integrated starter generator). These vehicles have no means of electric propulsion, the engine always drives the wheels. However, when stationary the ISG allows the engine to be turned on and off again quickly without the use of the ignition key. When in the off position the vehicle is using no fuel and producing no emissions. This means that average fuel consumption and average emissions are decreased when a homologation driving cycle is run. The frequent stop/start system can cause batteries to discharge quicker and so some form of regenerative braking is usually employed to convert wasted kinetic energy into useful stored battery power. Advantages: Conventional technology, limited change in architecture needed, inexpensive solution, some improvement in emissions and fuel economy. Disadvantages: Stop/start can be confusing at first, improvements in economy and emissions are limited and sceptics argue benefits are negligible in real-world driving. Parallel Hybrid (Self Charging) These vehicles have a conventional (usually gasoline) ICE plus an electric motor. Both the motor and engine can drive the wheels either separately or together. When pulling away, electric power only is used until the vehicle reaches approximately 20mph. Thereafter the ICE provides all of the propulsion and in addition charges the battery (regenerative braking is usually employed too). Under full load, the electric motor kicks in and provides additional power alongside the gasoline engine. An example of this technology being applied is the Toyota Prius. Advantages: True electric vehicle in that electric power does propel the vehicle under certain conditions, no need to manually charge the vehicle, no range anxiety, offers greater fuel economy, performance and lower emissions. Disadvantages: If used on shorter runs the battery never charges, as such it is propelled exclusively by the ICE. With the additional weight of the electric motor and engine, fuel economy and performance are reduced if in this mode. More costly to produce and more likely to fail due to ICE and electric motor. PARALLEL HYBRID (Plug-in phev) Propulsion architecture is the same as above, but the battery is replenished by plugging into a charger. With the ability to charge the vehicle, it can run for longer on electric power thus improving economy and emissions further. Examples of this technology being applied is the Mitsubishi Outlander PHEV. Advantages: Increased fuel efficiency, lower emissions, longer all electric range and thus cost/mile of motoring reduced. Disadvantages: Overall 'greenness' of using and ICE and e-motor is questionable; recyclability an issue as battery packs need more frequent changing, extra strain on national grid, no standardised charger, extra infra structure required. Range ExtenDED Hybrid Range extended hybrids have both an electric motor and small displacement ICE (500-700cc), but only the electric motor is connected to the wheels meaning all propulsion is electric. The ICE is used solely as a generator to charge the battery and as such can be optimised for this duty cycle (i.e. minimal changes in load/speed). This solution is really for those users where range anxiety is an issue. An examples of this technology being implemented is the BMW i3 range extender. Advantages: Reduced running cost per mile, high performance from electric motors, range anxiety reduced as engine can charge the battery, reduced weight compared to parallel system. Fuel economy and emissions can be zero depending how driven. Disadvantages: More complex and costly to produce than full electric; more a psychological fix than an ideal technical solution. Battery Electric Vehicle These vehicles have only an electric motor for propulsion– there is no ICE engine. As such they must be plugged-in to charge. These are pure all electric vehicles. Batteries are usually built as structural members, closely packed and fitted wherever there is space (usually floor to reduce centre of mass and thus vehicle handling). Examples of this technology include Tesla. Advantages: Zero emissions, lowest running costs, exhilarating performance, simple compared to ICE and thus price will fall with economies of scale, no local pollution. Disadvantages: Range is limited to 150-200 miles in good conditions, require owner to have charging point, long time to charge, pollution moved to power stations, investment in infra structure required, recyclability, battery flammability, architecture of vehicle significantly changed to reduce weight/improve dynamics. ​The Future of battery It seems most investment is going into pure BEV although several Japanese manufacturers see self-charging or PHEV as the winning solution. Regardless the race is on to increase range and decrease charging times. Here are a few changes we may see on battery vehicles of the future: More intelligent use of power: New heating/cooling technologies for HVAC, greener driving modes, intelligent connectivity that builds in charging stops (or reserves charging) into satnav. Solar cells (PV) cannot capture enough sunlight to propel a vehicle (at the moment) but could potentially be used to power ancillary systems and provide a trickle charge. Connected autonomous vehicles: The connected and self-driving car – if a car can navigate and drive itself, it can drive itself to local communal charging points while the owner is sleeping. Charging: Batteries that can accept a higher charge rate and an infrastructure than can deliver more power per hour, use of inductive charging, standardised plugs. Improved battery chemistry: Current lithium battery technology uses a 'slush' electrolyte, this is flammable and uses cobalt which is toxic. Improvements in battery technology include solid state, low cobalt electrolytes with ion carrying capability on par with slush. These will allow more tightly packed cells and thus overall higher energy densities and improved flammability safety. Chemists are also looking at sodium or even magnesium-based cells. ​WHAT ABOUT OTHER TECHNOLOGIES? Even with the improvements in battery technology, they will still have inherent disadvantages – time to charge, range, safety, additional infra structure. So are there any alternatives? Fuel cells: The use of electrolysis to combine oxygen (from air) and hydrogen (stored on vehicle) have been talked about since the 1950’s. They produce no noxious emissions and can be refilled like a traditional gasoline car and so surely this is the future? On paper they offer a lot, but in reality there are the following challenges to overcome – hydrogen infrastructure does not exist (volume production, storage and distribution), safety of storing hydrogen, reliability and durability are much lower than ICE. Very little R&D investment is going into fuel cells for cars (Hyundai excepted) and no government legislation has been shaped to hasten adoption. Its seems therefore that hydrogen is a dead end...or is it? Hydrogen as a fuel. Hydrogen is the most abundant element in the universe, has a higher energy density that gasoline or diesel and burning it as a fuel can be done in a modified ICE with no carbon pollutants (NOx may still be an issue). Furthermore, some vehicle by their nature eg PSVs, have duty cycles very unfavourable to current battery technologies (frequent stopping/starting, large volumes to heat, pressure to minimise down time. The challenges of hydrogen distribution and storage still remain, but some manufacturers are actively researching workable hydrogen fuel engines. So, there you have it! The future is electric we’re told. Unless it’s hybrid...or then again... is it hydrogen? Join the debate and let me know what you think.