January cover story: Automation, robots, Brexit and the year ahead

Here, Tom Bouchier, managing director of Fanuc UK, provides his view of how automation progressed in 2018 and looks forward into 2019 to see what challenges and opportunities face the UK manufacturing industry.

As we prepare for one of the most uncertain years in recent UK history, manufacturers are starting to plan ahead and look into new, more efficient ways of working. With Brexit and Industry 4.0 expected to dominate the news agenda for another year, manufacturers have an opportunity to progress and establish the UK’s manufacturing presence once again.

Following recent research that suggests the country is falling behind its European and global counterparts, new technologies and equipment, such as automation and industrial robots, can play a supporting role in this progression.

Where did 2018 leave the UK automation market?

Current estimations state the UK is going to remain behind other leading manufacturing nations until 2022, with the likes of Germany currently having a higher production rate of 30% per hour. According to the International Federation of Robots (IFR), there are just 71 industrial robots per 10,000 workers in the UK. That positions the UK behind 14 other European countries. In contrast, Germany – Europe’s most automated country – has 309 units, whilst the Czech Republic, the closest European country to the UK, has 101 units per 10,000 workers.

Additionally, the Budget, announced in October, won’t necessarily help the UK bridge this gap, with much of the projected funding being placed in long-term projects looking into developing technology. While it is very important that new research into technology is commissioned, the UK needs investment into automation now, as it could be in danger of falling even further behind its European counterparts.

As technology advances and the UK starts to introduce 5G technology, manufacturers need to understand how this technology can link to everyday plant processes. If manufacturers are not equipped with automated systems or up-to-date technology, it is unlikely that they will be ready for the benefits of new technologies such as 5G, and therefore run the risk of continuing to trail in Europe’s footsteps.

2018 has seen some positive improvements for UK manufacturing, especially linking with automation. While it isn’t directly linked to the Autumn Statement, we are seeing manufacturers slowly starting to adopt new technology and more automation. This trend, which was started by other countries a decade ago, is an important step, but there are still those that hold negative views about automation and the role it can play to assist their processes. This perception needs to change in 2019 if the UK is going to catch up with the rest of the world.

Changing perceptions

One of the changes industry needs to focus on in 2019 is the perception of automation within manufacturing. ‘Robots’ is a global term and it is very easy to be misunderstood – government and industry bodies need to work together to change its perception. Whether it is the widely claimed links between automation and job replacement, or the general perception that manufacturing is not seen as a viable career choice at a young age, 2019 needs to be the year this changes.

Upskilling

Let’s start with automation and jobs. The UK is the only G7 country with a robot density below the world’s average. Currently, there seems to be a stigma attached to the use of robotics and automation and linking it to unemployment, but many manufacturers are missing an opportunity to upskill their current staff.

There is a clear upskilling opportunity where automation is concerned. Fanuc, for example, has a dedicated training academy at our Coventry headquarters which engineers can use as part of the bedding-in process, both pre- and post-sale.

Introducing automation and robots to a plant can mean engineers can learn how to programme and maintain the machines which could, in turn, lead to greater productivity rates. Programming can take as little as four days, meaning the number of skilled engineers could increase sharply across the UK.

Affordability

The final perception that requires change is the affordability of automation. The perceived costs often wrongly associated with industrial robotics can often play a role in UK manufacturers choosing not to adopt new technology in their plants. However, industrial robots are not as expensive as people think and, on many occasions, the return on investment can be recouped in as little as 18 months.

As automated systems can be reprogrammed, industrial robotics offer manufacturers a long-lasting solution that goes beyond first use. If this is then coupled with the training of engineers to be able to programme robots, it has more benefits than originally thought.

Apprenticeships

The image of manufacturing to young people also needs changing. The industry needs to be more of an attractive proposition to those who are starting their career journey and, with the role that automation is going to play in UK manufacturing, it is possible for this to change.

Schools need to ensure that a career in this industry is promoted as an option. Manufacturers, too, can also play their part by appropriately promoting apprenticeship programmes and making them accessible to those interested in applying.

However, it would be good to see the delivery of apprenticeships slightly change. It is important that apprentices in manufacturing spend time learning the entire process of how a plant works, rather than focusing on one or two departments. Having this clear vision of the different processes will help train young people and keep them engaged that a career in industry is more than just one process.

2019 Forecast

As previously mentioned, improvements are being made by UK manufacturers but some sectors are still slow to adopt new technology and automation. However, Fanuc expects to see further growth in automation across a number of sectors, including many areas that have yet to utilise it.

One of these sectors is food manufacturing where Fanuc has started to receive a rise in enquiries from a number of different companies. Despite being the UK’s largest manufacturing sector, it has been a historically labour-intensive industry. Automation will, however, be a key driver in supporting food processors improve their productivity levels.

Innovative use of technology is also likely to be an important trend. In 2018, Fanuc assisted KMS Projects develop a ‘breakthrough’ selective automated broccoli harvesting system, which has the potential to revolutionise the UK vegetable industry. As the industry faces spiralling production costs, it is inventions like these, which saw three Fanuc 6-axis M20iB robots mounted onto a rig, powered and driven by a tractor, that require further support from the government.

As it stands, Brexit is still the great unknown and, while we expect a period of uncertainty when the UK eventually leaves the EU, we see it as an opportunity for manufacturing. In order to compete with leading countries, the UK is going to need to manufacture more and adopt new technologies. Manufacturers will therefore need more support in understanding how the adoption of automation, as an example, will help their business and how to make the important first steps.

Industry 4.0 is only going to evolve in the next 12 months and Fanuc is already looking at new products and ways to help the market. UK manufacturers need to do the same, otherwise we are likely to fall further behind the likes of Germany, Japan and USA.

As we look forward into a new year, it is clear that UK manufacturing has an opportunity to grow and change its perceptions. Automation and industrial robotics can play a big role in achieving these goals, but the industry must work hard in changing the views of how it will impact productivity, budgets and employment. If attitudes change and more support is provided, then 2019 could be the year that sees the UK increase its productivity and re-establishes itself on the global manufacturing map.

Fanuc UK www.fanuc.eu