Advanced Manufacturing Lessons Learned from the UK

The MTC journey (in 20 months…) Nov 2011Aug 2011Nov 2010March 2010

The MTC journey March 2010

The MTC journey Nov 2010

The MTC journey Aug 2011

The MTC journey Nov 2011

Still one of the largest manufacturers in the world Approximately half of each Airbus is made in the UK Rejuvenated automotive industry Home to 70% of Formula One teams Preferred location for food manufacture & export World class research and academic institutes UK Manufacturing 2/10/2012© 20127

The UK has a world class academic base …..but UK plc. has failed to capitalise on the early stage research coming out of Universities The UK Value Proposition 2/10/2012© 20128

The Completed Capability Pipeline The Complementary Funding Pipeline The Completed Capability Pipeline The Complementary Funding Pipeline 2/10/2012© The MTC Partnership Solution Research PartnersIndustrial Members MTC Basic Idea Concept Developed Proof of Concept Process Validation In Lab Process Validation Production Scale Process Capability Validated Capability Validated Economic Run Capability Validated Range Of Parts Capability Validated Over Long Period EPSRC Business TSB

Manufacturing Technology Centre  Purpose:  To improve the business performance of our members by providing novel and well developed manufacturing solutions  Founded by leading research organisations:  University of Birmingham  Loughborough University  University of Nottingham  TWI  12,000m 2 facility set up with £40 million of public investment 2/10/2012©

Research Themes 2/10/2012©  Originally FOUR core research activities:  Intelligent Automation  High Integrity Fabrication  Advanced Tooling & Fixturing  Net Shape Manufacturing

Research Themes 2/10/2012©

 Additive Manufacturing (AM)  Net Shape Hot Isostatic Pressing (HIP)  Diffusion bonding  Non-Destructive Evaluation (NDE)  3D measurement – internal & external  Research partner: University of Birmingham  Active projects: Rail wheel cladding & Medical implants Net shape manufacturing 2/10/2012©

 Rotary Friction Welding  Automated Joining Processes  High Accuracy Arc Welding  Laser Processing  Joint Analysis and Testing  Research partner: TWI  Active projects: Automated welding of aerospace components High integrity fabrication 2/10/2012©

 Elimination of manufacturing induced defects  Automated in-line inspection  High variety, low volume, very complex products  Human-robot cooperation  Process control & monitoring  Research partner: Loughborough University  Active projects: Automated turbine blade manufacture & Sticky food handling Intelligent automation 2/10/2012©

 “Right-First-and-Every-Time” rapid product setup  Reduced jigs and fixtures inventory  Metrology-assisted control of process error build-up and propagation  Mechanical or electronic in-process adaptive control of clamping forces to improve product and process stability  Research partner: University of Nottingham  Active projects: Multi spindle drill head & Automated sealant application Advanced tooling & fixturing 2/10/2012©

 Elimination of manufacturing induced defects and adverse reliability impacts  Solder-free packaging/assembly  Development of higher temperature tolerant materials and interconnects  Development of new materials and manufacturing processes  Research partner: Loughborough University  Active projects: EV-Lite & Intellico Electronics manufacturing 2/10/2012©

 Process simulation  simulation of static & dynamic scenarios  Cell simulation  cell design/layout, cell operation optimisation  Production line simulation  assembly simulation, factory layout optimisation  Overall operation of facility  cost modelling, supply chain configuration/design/risk  Research partner: University of Birmingham  Active projects: Low drag aircraft wing simulation Manufacturing Simulation 2/10/2012©

Tier 1 Tier 2 Tier 3 Current Membership 2/10/2012©

MTC Membership: Industry split 2/10/2012©

3 15 > >70 Apr ‘11Nov ‘11May ‘12 New members New employees 5 >30>60 New projects Rate of Growth 2/10/2012©

What can MTC do for you? KNOWLEDGE  Sharing knowledge, info, best practice  Access to experts  Access to non- confidential research SERVICES  X-thematic R&D  Consultancy  Tech transfer  External research funding  Advice  Training NETWORKING  Cross sector  Supply chain  TIC  KTN’s  Showcase technology  Conferences/ seminars RESEARCH  First access to TRL1- 3 research  Significant gearing  Engage in OEM & Tier 1 supply chains FACILITIES  State-of-the art equipment:  Production  Inspection  Test 2/10/2012©

 In March 2011 the UK Government announced the formation of a number of Technology Innovation Centres (TICs) – now known as “Catapult”  The HVM Catapult is the country's first technology and innovation centre and will act as the model for others to follow  Intended to provide an integrated capability and embrace all forms of manufacture using metals and composites, in addition to process manufacturing technologies and bio-processing HVM Catapult 2/10/2012©

AFRC NAMRC AMRC NCC MTC WMG CPI HVM Catapult Centres 2/10/2012©

Ansty Business Park 2/10/2012©

Manufacturing Technology Academy 26

Contact Details  Steve Statham  Business Development Manager   Tel: Inspiring Great British Manufacturing 2/10/2012©