Manufacturing Engineering

and Metrology

Ian Wilcox

Senior Lecturer in metrology

Engineering is seen by Government as a key contributor and are targeting future growth in GDP and export through Advanced manufacturing

We are living in a skills shortage, soon to become a skills crisis

New apprenticeship frameworks and funding via the voucher scheme are all in the near pipeline

Etc……………

Change is often the best time to find opportunity

Metrology is a key pillar in manufacturing engineering and central to factory 4.0

All the ingredients for a perfect storm

What do we define as metrology?

‘the scientific study of measurement’

We also include the application of the lessons learnt through that studyWe call this ‘applied metrology’

Metrology includes seven base measurements called standard Index units (S.I. units). These represent the seven physical units.

• Length (Metre)• Mass (Kilogram)• Time (Second)• Electric current (Ampere)• Temperature (Kelvin)• Luminous intensity (Candela)• The amount of substance (Mole)

Most industrial employer focus is on length, also known as dimensional metrology…….. They call it industrial measurement

The result is applied dimensional measurement.

Industry use it to drive

• Pass/fail• Process control• Continuous improvement• Quality indices• Cost efficiency• Etc……..

It therefore contributes the data that we use in key decision making within a businessMetrology feeds decision making from design concept to shipping

Throughout the manufacturing process metrology exists

Design - effective application of datuming and tolerancing (GPS) – ‘Design for manufacture’

Manufacturing – setting up, pass / fail, statistical process control - ‘Process control’

Quality - Control, validation, assurance, calibration – ‘standards and traceability’

Assembly – assisted assembly and validation – ‘Automation and final test’

Getting the above right• Reduced scrap• Reduced warranty (in field failures)• Lean processes / costs reduction

Getting it wrong• Reputational damage• Spiralling quality costs and waste• Poor decision making

Simplistically we could say

Companies sell on a combination of quality and cost, both are fed and sustained by data from measurement.

The trick is getting the right balance

If we had confidence in the process we would measure very little.

But metrology and other key technical skills suffer from a malaise

• Awareness and perception• Poor leadership and management• Lack of underpinning knowledge• Viewed as an indirect activity – non productive

• Skills and competence• No clear indication of competence and qualifications• Poor professional development opportunities• Small talent pool

• Technology• Computer aided metrology• sensor and system technology• Mass data requirements

Often the missing link or poor relation in Lean. Continuous Improvement and TQM

We need to reverse these employer trends

Metrology has drifted into the shadows, assumptions rule. Measurement just happens

• Good practices have not been continuously developed to keep up with new manufacturing techniques and measurement technologies

• Standards have left behind all those that are not at the pinnacle of the science and therefore they are disengaged

• Medium / long term investment has been cut

• Supply chain failures

Historical pathways for measurement specialists and metrologists

• Machine tool operators, particularly toolroom machinists (manual)

• Apprenticeships often had a formal and valued inspection module

• Mentors and on the job training embedded that training

It was a simpler world

Employer investment

in skills

Mentors and leaders

Equipment technology

Talent pool / pipeline

Advanced manufacturing

techniques

Skills reports

(2005) Leitch report: ‘..skills 12th out of 18 comparable economies’

(2015) ‘The UK needs nearly 2 million new skilled engineers over the next 5 years’

2 million skilled engineers over 5 years, that means 400,000 per year

Roughly = 200,000 apprenticeships200,000 graduates

Current output 60,000 apprentices50,000 graduates

(BTW) 3 years for completionGet ready for this. Get involved

• Computer aided measurement is almost an essential

• Sensor technology additions have given us more options

• Technology, software and interface have added capability

In the worse cases skills are reduced to which button to press

Measurement has become a little black box that is poorly understood and gives over simplified answers

In some this has created an ask no questions culture

Technology has made some giant steps in recent years

Summary

Metrology should add value by reducing costs and managing risk. In reality it is all about risk management, how you apply metrology is how much risk you can afford

Who in your business looks after this and do they have all the tools they should have

What does failure look like these days? Well it’s not a cliff anymore. The big bang failures have receded and become rare. Today’s failure is far more subtle it’s getting most of it right but missing one key ingredient that produces a steady decline and

eventually failure, often without an understanding of why

Poor metrology is hitting big and small, rich and poor companies equally

It’s about small steps not revolution, a journey of improvement often starting with ‘do I understand the problem and its root cause’

What is the opportunity?

Collaboration

• Two metrology trailblazers have been listed

• Partnering with a UK lead organisation who can mentor and CPD

• Possible technology partnerships if you go further

• Offering employers a skills and qualification pathway

What is the opportunity?

Employer engagement

• Employers are looking for skills training and qualifications in this area

• We engage with over 300 employers a year in metrology and its growing FAST!

• last year we had over £250,000 income from short courses alone, a growth of 30%

• Employers funded 100% of this no government money

• They will need local deliverers for the trailblazers

What is the opportunity?

Low risk

• Core skills don’t require a massive investment in equipment, most you already have

• We have generated a bow wave that you can tap into

• Rapid changing technology and knowledge is something we can give you access to and support you with and give access

• Credibility of partnering with Coventry University metrology team

What do we offer you?

• Upskilling in metrology with train the trainer for your own staff

• Provide ongoing CPD and support to your staff

• Offer a pathway post your own delivery

• Provide materials if required

• Work with you on employer engagement

• Help you make a start

• If you already deliver lean we can help you link metrology to it

How can you get involved

Talk to us to see what if any opportunity exists

Charles Darwin – ‘Survival of the fittest’

Those that survive are those best adapted for their environment

Thank youIan.wilcox@coventry.ac.uk