< Previousbmta.co.uk The second premise is around the use of virtual reality to de-risk change. The visualisation of the reconfigurations of production lines or the new layout of existing premises where there may be a need to get stakeholder feedback are increasingly common. It is now routine to engage a workforce in a virtual scenario, to gather first-hand input from the people who will actually be on that shop floor. The third area in which VR is seeing extensive uptake within manufacturing is in training, assessment and certification. Training in a virtual environment achieves many things; it is less risky than using real-world processes, it is highly repeatable, it has the potential to reduce the use of materials during the training phase, and most importantly, it can be gamified. Gamification is the ability to set a scoring metric against a repeatable scenario, and allows the use of virtual environments to introduce, teach and then evaluate worker progression. It also enables peer group competition to drive self-learning, thus accelerating the uptake of new skills or the understanding and refining of new scenarios. Multinational corporation 3M offer a package of VR safety training to prevent trips and falls at work, to reinforce training behaviour. The VR system allows supervisors to walk around a virtual site to identify hazards and safety violations and to inspect workforce PPE. Example tasks are also included, such as installing a steel beam or corrugated flooring. The benefit of this virtual training is that the student is not exposed to any real hazards during the training and the system allows multiple training courses and scenarios to be completed without travelling between sites. General Electric is using VR to train new staff to operate cranes to install high-voltage grid components. Training times have been reduced from days to just 20 minutes using VR, removing the need for physical training hardware and associated support. However, the final stages of training are still completed on-site with physical hardware. This shows how VR can enable training to be delivered in safer environments, for example students can be trained inside an office or even at home, away from industrial hazards such as high voltages. (https://www.ge.com/news/reports/virtual- reality-heavy-lifting-grid-technicians-training). AR in manufacturing The role of AR in manufacturing is, as yet, less well refined. Nonetheless, the range of use cases for this technology are expanding every day. The most common use cases of AR include remote support, data overlays, hands-free digital work instructions and assisted inspection. Remote support is probably the simplest, and is yet likely to be the most effective use case of AR. Assuming a minimum level of network connectivity, a remote viewer can ‘look through the eyes’ of the person needing assistance and annotate the view with instructions or comments. This makes it easier to convey complex instructions and if wearing a HMD the operator can immediately implement the guidance. This also enables a one-to-many relationship between experts and workers in the field, mitigating some current skills shortages. Given the ongoing pandemic, remote support is likely to be especially important at the current time with the need to socially distance and minimise travel. The experience can be further enhanced with the remote expert using VR, giving them a more similar view and experience to that of the factory operator. A recent example of how AR has been used to upskill workers was seen during the recent VentilatorChallengeUK, a nationwide response to the pandemic-induced need to manufacture ventilators at a previously unimaginable scale and speed. The Microsoft HoloLens 2 was deployed across a number of assembly sites tasked with manufacturing thousands of ventilators. This technology allowed aerospace and automotive operators to be reskilled to assemble ventilators, receiving step-by-step instructions about the devices they were assembling, in the context of the assembly station they were working at, all while working hands-free. These devices also enabled experts to remotely ‘dial in’ to the devices to provide individualised one-to-one support in real-time. The delivery of contextualised data to operators on the factory floor is another prime use case for AR. A viewer can be looking at a piece of manufacturing equipment, with real-time data feeds delivered in the spatial context of the equipment itself, which for example could provide direct monitoring feedback. This data could be low level information from the machine, for example spindle speeds or temperatures fed from connected sensors, or could be processed to give higher level information such as that related to current production or failure rates. The AR system can be extended to offer a virtual control panel allowing the user to interact with higher level devices, such as control systems or update a manufacturing execution system (MES). A specific application for contextualised data delivery via AR bmta.co.uk is digital work instructions. This is especially important for flexible manufacturing, a cornerstone of Made Smarter. An AR HMD can be used to deliver the latest, version- controlled work instructions tailored for each operator’s competencies. These instructions can be interactive, offering the user more or less information on specific tasks. The AR device can also be used to request inspections, report issues and report real-time work progress allowing for dynamic process planning. Many of the more comprehensive mixed reality HMDs are able to display 3D CAD models, spatially anchored onto the current work piece, which can simplify complex multi-component assembly or can be used to guide inspection. Boeing has developed and assessed an AR-based tool, which could achieve a 90 per cent improvement in first-time quality when using an interactive AR model, compared to using 2D information on a wiring loom assembly task. https://www.boeing.com/features/2018/01/augmented- reality-01-18.page AR is seeing earlier integration into manufacturing equipment, even at the equipment installation stage. For example, Stahlwille and a German start-up, oculavis, developed an AR solution which not only took the user through the set-up instructions for a torque wrench and the bolt torqueing sequence, but also gave a heads-up display of the torque values, before automatically writing those values to the production planning and control system. Over the next few years, this type of integrated system will become more commonplace on the shop floor and will even be embedded in the audit trail, as they do not just capture the bolt torque values but also the identity of the operator. What is more, through the uses of integrated systems, the operator could even pull up a virtual version of a calibration certificate to ensure that the equipment is still within calibration. Having said that, the augmented experience is just displaying the values that have been captured from embedded systems within the tool that are connected to the head set through Bluetooth or other communication protocols. https://www.stahlwille.co.uk/en/products/news-detail/news/ augmented-reality-ar-to-complement-torque-technology/ In 2017 Thyssenkrupp, a manufacturer of home mobility solutions, announced plans to equip their sales people with Microsoft HoloLens AR HMDs to measure staircase dimensions during site visits. The HMD would then automatically share the staircase dimensions with manufacturing teams to reduce data entry time, transcription errors and decision-making time. Many AR devices now offer the capability to measure in augmented space, which is even available on some mobile phones. However, this technology is still quite immature and measurements done in an ‘app’ suffer in many ways, from problems with the positioning of the point to be measured, to the accuracy of the sensing technology itself with different phone types producing widely differing values. It is expected that this technology will improve quite rapidly, especially with the increasing availability of better accuracy sensing technologies such as miniaturised solid-state Light, Detection and Ranging (LiDAR) and multi-camera systems. However, there remains some underlying challenges in the interfaces. Augmented Electrical Cabinet: The AR electrical cabinet demonstrator features a Microsoft HoloLens HMD which was used to deliver work instructions to an operator performing wiring commissioning checks on an electrical cabinet. The project highlighted the use of digital work instructions for improved productivity and quality. The system that was developed integrated a voice activated multi-meter to allow operatives to view meter readings on the HMD, record readings and maintain complete focus on the task. The test results were able to be taken directly from the device (rather than have an operator write them down). Time savings in excess of 30 per cent were achieved compared to an installer using paper- based instructions. AR doesn’t always require customised hardware such as HMDs which can come with hefty initial investment. Older, more readily available technologies such as optical or laser projectors are an option too. These can be used to project diagrams, work instructions and other information directly onto a work piece. This approach keeps the workforce hands-free and requires little training and up-skilling. Projected AR for construction: This use case was conducted with a major player in the construction sector and featured the use of optical projection systems to assist operatives during the ‘setting out’ process, whereby an operator can project work instructions directly onto the fabric of a building. The AMRC worked with the company to ensure that data created during the design phase of a building could be exploited on-site with minimal processing steps. The system enabled operators to work with unprecedented speed (~50 per cent time savings, compared to using paper based drawings) and ensured a strong link between the design intent of the architects and the construction teams. The output of the project is a system which it is intended to roll out across existing and future construction projects. Video: Case Study: https://www.amrc.co.uk/files/ document/292/1557330103_SmartSet_case_study.pdf So where next? While VR and AR technologies have been around for decades in various forms, it is only now that we are beginning to see the enabling technologies evolve to such a state wherein there are no longer major barriers to their adoption and deployment. The advent of 5G will enable greater numbers of fully mobile devices to be connected with lower latencies and higher bandwidth. The evolution of artificial intelligence (AI)-driven software platforms for VR and AR based content authoring will enable the adoption by companies of the technologies, without the previously eye-watering budgets for content creation. The development of industry standards will allow greater interoperability so that the hardware is no longer the bottleneck, and on that hardware, greater processing power combined with improved power consumption and next generation sensors at consumer prices will open the potential for adoption of these technologies at scales of which the pioneers of this technology could only dream. The future is bright, the future is digital…bmta.co.uk USING DIGITAL TRANSFORMATION TO BENEFIT YOUR BUSINESS by Tim Daniels, Marketing Manager, Autoscribe Informatics A potted history of industrial advances The 1st industrial revolution used the power of steam and water to move away from hand production to machines in the 18th century. The 2nd industrial revolution drove mass production and the improved efficiency of the modern production line in the 19th century. The 3rd industrial revolution, also known as the digital revolution, occurred in the later 20th century, where computers and communication technology drove innovation and efficiency. The current, 4th industrial revolution, is being driven by digital transformation, the interconnectivity of everything, and the use of computing power to automate decision making. What is digital transformation Digital transformation uses digital technologies throughout an organisation to fundamentally improve or change how businesses operate and provide value to their customers. Digital transformation may encompass multiple systems and technologies including robotics, workflow automation, advanced data analytics, artificial intelligence (AI) and Cloud technologies. Bringing together disparate systems to seamlessly manage data is at the very heart of digital transformation. This requires unified multi-directional flows of data and information from every part of the business, creating an interconnected data ecosystem. Nowhere are these ideas more applicable than in the laboratory environment. Laboratories provide a rich and varied source of data that is important to, and has value for, the wider enterprise. However, all too often this data exists as silos of information that is difficult to link. Figure 1 provides a simplified view of the multi-layered informatics model that can exist within a manufacturing organisation with a QA/QC laboratory function. The term ‘fourth industrial revolution’, or industry 4.0, is often used to indicate the ongoing automation and integration of traditional manufacturing and industrial practices, using modern technology. The term was introduced in 2015 and was the theme of the 2016 World Economic Forum in Switzerland. Industry 4.0 encapsulates the ongoing digital transformation of business, connecting processes and pools of data to make better decisions faster. Figure 1: A multi-layered informatics model of a typical manufacturing businessbmta.co.uk Using a LIMS to connect islands of data As the diagram shows, the laboratory does not work in isolation from the rest of the organisation or enterprise. It both produces data for the rest of the enterprise and consumes data from the wider business. However, this only works efficiently if significant issues around how the data is generated and stored, as well as questions around data compatibility and accessibility are addressed. Placing a configurable Laboratory Information Management System (LIMS) at the centre of your laboratory informatics strategy can make a significant contribution to the digital transformation of your organisation. The LIMS can record and manage data associated with a myriad of laboratory activities over and above those just associated with sample testing and make the data accessible within a standard database. In this way, the ability to easily search a single source of data allows better, more informed decisions surrounding all aspects of the laboratory to be made. It can also provide the all-important integration with wider business functions. Indeed, the ability to integrate with a variety of other systems has become a key selling point for the Matrix Gemini LIMS. Examples include: • Integration with complex instrument data systems, such as Chromatography Data Systems, to automatically schedule sample runs and collect the generated results • Initiating testing based on batch information passed from an Enterprise Resource Planning System (ERP) or Manufacturing Information System (MIS) • Linking laboratory data to other business data to allow visualisation of corporate data using business intelligence tools • Automated creation and delivery of invoices ensuring commercial customers are correctly charged and revenue is maximised • Allowing external customers direct, but limited and controlled, access both to request work to be undertaken and to review data and information • Remote access allowing, for example, tests to be approved even if managers are located off-site • These are just some examples of the capabilities of a LIMS to create, consume and distribute data and information of value. Furthermore, by providing access from a single integrated source to the type of operational and management data described above, the LIMS can be used to model the effect of potential business changes. For example, the impact of a new production line on the time to complete product testing and therefore product release, or the implication of winning a new contract on labour and equipment requirements in a commercial testing organisation. The LIMS becomes a business-critical system that enables informed decisions to be made regarding a multitude of laboratory processes. Integrating LIMS with Enterprise Systems – The Key to Digital Transformation All organisations are unique, and the aims and benefits that can be achieved through digital transformation will also be unique. To maximise the benefits of digital transformation the systems deployed must support this uniqueness but also be able to adapt to change. The key to this is the ability to configure the system to meet the needs without compromising its supportability. The configuration tools available in a fully configurable LIMS, such as Matrix Gemini, allow solutions to be built without compromising the underlying code. At least one organisation has used the product to create a complete business management tool linking the commercial and scientific aspects of the business in a single system. More commonly organisations integrate LIMS into their IT ecosystem, linking business critical systems to streamline operations. For example, the integration of a veterinary pathology laboratory to veterinary hospital management system to manage the care of valuable equine patients. Revenue can be maximised in a commercial testing laboratory by providing full details of all analytical procedures carried out as part of an agreed contract to the relevant finance systems. Conclusion A LIMS provides a powerful component to drive the digital transformation process in a business. While the 4th Industrial revolution is still in its infancy within laboratories, instrument sensors, robotic systems and other equipment is slowly becoming more connected, allowing data to move between them and the LIMS. Higher level (ERP/MIS) systems are being used to pass information and plan testing. Embracing and using digital transformation yields significant financial benefits to a business. Many of these benefits have been highlighted by current Covid-19 working restrictions and pressures on the economy. Like the previous industrial revolutions, the trend towards automation and data exchange in the 4th industrial revolution is unstoppable.bmta.co.uk AUTOMATED CALIBRATION OF NON-AUTOMATED DEVICES By Matt Gypps, UK Technical Manager, Trescal Rethinking automation Automated measurements have been possible for many years through the introduction of instrument interfaces such as the GPIB and programmable software such as Fluke MetCAL. Automated Test Equipment (ATE) enables faster measurements while maintaining accuracy and removes the potential for human error. However, devices without an interface remain reliant on an operator to make settings and interpret and record results. Until now…. Trescal, along with Thinkbot Solutions and Linestar Automation, developed a robot that precisely mimics the physical movements of technicians. “When we initially came up with the concept, many people thought it was laughable”, says Adam Webb, Regional Technical Manager, Americas, at Trescal. “The calibration process for these DMMs can only be carried out by turning knobs, pushing buttons and visually observing and recording results – so how could it be done without human intervention?” Matt Gypps, UK Technical Manager for Trescal, adds “we know this has been tried before and either failed or was only successful on a limited range of products. A system that can be used for any shape or size of handheld DMM is a real breakthrough for Trescal and the UK.” First launched in Trescal’s Dallas facility, the DMM robot is composed of a mechanical arm with 6 joints, allowing it to articulate in multiple positions compared to a human. It can pick up a wide range of tools and apply exact pressure, enabling it to calibrate standard DMMs with extreme precision. Not only can it calibrate the equipment, the What was once thought to be a manual-only calibration process is now being performed by a purpose-built robot. We take a look at how digital multi-meter calibration is being transformed by new technology and ask what the breakthrough means for other highly manual tasks. Used by field technicians all over the world, digital multi-meters (DMMs) are a standard diagnostic tool for testing electrical values. These handheld devices need to be calibrated periodically to ensure they remain accurate and reliable, but many DMMs are not equipped with a means of communication, i.e., they have no port for USB, RS232 or similar standards. This meant that calibration was undertaken manually, with technicians required to manipulate the devices, read values on the LCD screen, and record the results. Recently, this time-consuming process was completely reimagined by the design of the first DMM calibration robot.bmta.co.uk robot can pick up the next piece of equipment in the line for calibration enabling up to 14 handheld DMMs to be processed in each session. The only Manual intervention required is to keep the robot’s assembly line stocked with DMMs. Once the technician has performed some basic checks and loaded the system, the measurement process and certificate production are entirely autonomous. This not only reduces the calibration time and minimises errors, but the technician can invest their time in more challenging activities. Deployment of the robot in the UK Trescal’s Stevenage branch was picked for the UK launch of the robot as the branch already had four manual systems in operation. Calibration requirements are similar around the world, but not the same. The system had to be programmed to meet the stringent requirements of the UK market and pass a UKAS assessment to enable it to be used for accredited calibration service per the requirements of ISO 17025:2017. Thanks to the flexibility of the design, the system can be used to calibrate any handheld DMM. Physical Digital, the latest acquisition from Trescal, scan each DMM using their 3D structured light measurement solution to add accurate dimensions to the nest template, which is then printed on a 3D printer in the laboratory. This custom carriage fits snug around the device and enables it to be loaded on to the conveyor. Locations of the DMM terminals and controls are all preprogrammed to enable full autonomy of both switch rotation and cable placement. Benefits of automation After two years of use in Trescal’s Dallas Branch and feedback from proof of concept, the results show that the robot calibrates just as precisely as highly-trained technicians. The time required for calibration is roughly the same (between 18 and 35 minutes per DMM, depending on the complexity of the device). Still, the real benefit is that the robot frees up technicians to concentrate on more demanding metrology tasks. Technicians no longer have to spend much of their day doing what is essentially routine calibration work and can now focus on their development in other areas. In addition, the robot can carry on working outside usual shift hours which allows for work to continue after staff have left for the day, provided DMMs have been loaded on the system. Matt Gypps explains, “We have proven using a robot does not have any negative impact on the quality of our measurements. It has allowed for more time to be spent focusing on future innovations.” Sharing knowledge Having demonstrated successful improvements for the Stevenage laboratory, Trescal is now able to deliver DMM calibration to other parts of the UK via their transportation network. DMMs are designed differently; therefore, it is necessary to create a separate configuration file for the robot each time it calibrates a new DMM type. The file contains details about the device, such as the positioning of dials and input jacks, or the size of the screen. The files can be shared with users of similar robots in other Trescal laboratories in the UK or in any international laboratory. “We wanted the configuration process to be simple, so technicians didn’t need programming skills”, explains Adam Webb. “That’s why we developed the robot with partners who were experts in LabVIEW and could deliver a user-friendly interface. Thanks to the work of Thinkbot Solutions (programmatic design and robot integration) and Linestar Automation (mechanical and electrical systems), the robot can be configured to operate on a new DMM by anyone with basic Excel spreadsheet skills. Each new configuration file can then be shared across Trescal’s facilities.” Inspiration for further applications Since the robot automates physical actions and translates operations into measurements, the possibilities are endless. “Now that the robot is embedded and has successfully passed a recent UKAS assessment, we are investigating the potential to use it for other manual calibration activities in a number of parameters”, says Matt Gypps. “The potential is exciting and no longer just a concept.”bmta.co.uk INDUSTRY 4.0 AND THE IMPACT ON THE MEASUREMENT, TESTING AND CALIBRATION PROCESS By Brian Waterfield Consultancy Ltd Firstly let’s get the elephant in the room out in the open! Nostalgia has no part to play in our digital future. What I mean by this is that old ways are just that, old! Digital gives teams a clear sight of what needs to be done in a business. These needs cannot be held back by old fashioned values of “if it’s not broke then don’t fix it”! The only way to become, and remain competitive, is to take a fresh eye view on operations. There is no need to panic, as this is not an overnight solution. You need to plan, act and change. However, when I say plan you cannot afford to plan for so long that your business or operation processes become obsolete. So let’s take a walk through the descriptions in relation to operational processes and build context around actual, rather than complete, visionary planning. In the world of measurement and test, digital has been around a long time, offering greater accuracy and simplicity of process. But the digital demands that come with Industry 4.0 are weighty, and every area needs to adapt. Understand what going on Measurement and Test has been a core attribute to keeping a standard of accuracy and quality. The digital age demands the same sort of rigour to understanding your business, enabling effective transformation and increasing process adoption by understanding your complete product development life cycle. Digital technology, Industry 4.0, AI, virtual, augmented, mixed reality, digital twin; the words that are becoming commonplace in our digital vocabulary. But what does this actually mean to industry?bmta.co.uk Identify data requirements When you build your process maps they give you the opportunity to see your data gaps. These gaps can give a great insight into failure modes, efficiency improvements and the technology implementation strategy. Establish data capture storage and translation Use the data to drive change, measure and test outputs, then make the data accessible through visualisation Visualisation This next step covers all outgoing data, making it simple to understand, interact and drill down into the detail. The visualisation plan should start to create an open, sharing culture and provide access to information that helps see a clear view across the business. So, moving away from the vision to implementation and actual applications that are currently being used today in automotive, or are part of this transformation ideal. Quality is driven through measurement and test! To make a difference the data feeds industry is looking for more monitoring, greater transparency and contextual live simulation. Simulation and virtual commissioning are growing in their effectiveness through greater virtualisation, more powerful computation, and a wider reach to stakeholders. The chicken and egg scenario Correlation is key to effective change from real to virtual. Trialling and testing the process physically is the only way to get the data required to trial and test virtually. One advantage that virtual provides, is the ability to change the parameter offered in tests that may not have been achievable in a real-world setting, especially in time- restricted processes. Real data feeds and the virtual test replaces the real event once the process has been measured and tested to remove uncertainty. The role of inspection, measurement and testing has widened to not only check the output of physical activities but also to supply the virtual simulation with the facts it needs in order to become credible. In practice, Industry 4.0 is driving the industry to take a closer look at things, implementing sensors to capture data, introducing monitoring to search for efficiencies and driving a program of artificial intelligence to build up the unknown. Industry data capture is a company script for the future and, in adopting measurement and test, rigorous attention to detail is the pillar for change. In process: Sensors within active cells: The automotive industry is increasing this monitoring technique to deliver a clearer picture. Virtual commissioning: The automotive industry uses this to double-check everything. However, they are beginning to transfer to simulation and less to physical test. Production efficiencies: The automotive industry is using data to run multiple scenarios enabling safe and robust decision making. Digital Twin There are many versions for explaining the term digital twin, but in its simplest sense it’s a digital mirror of a physical process, part, product or system. The automotive industry and many others are building their strategy around a digital twin mindset. This mindset will see more and more simulations that are generated in real time and can interact and react to actual physical events. Automotive has been proactive in creating digital twins of their products, but this digital age has shown that process is as important as the product – the modelling of the complete lifecycle is fundamental to your future. One cautionary note is that digital twin should not just be a mirror of operations, but an author of your operations, underpinned by quality measurement and test.COMPANY PROFILE INDYSOFT bmta.co.uk Almost 20 years of continuous development – based upon thousands of global license sales – has enabled IndySoft (www.indysoft.com) to understand industry requirements. The current COVID crisis has impacted sales slightly and a surprising number of clients pulled their orders forward in order to utilise their quiet period to get IndySoft installed and configured so that they can utilise it as soon as work ramps up again. We have noticed an increasing number of clients opting for their installation to be on IndySoft Cloud. This option removes almost all of the burden of internal IT departments and frees them up for other things. The IndySoft cloud automatically manages the server space, speed and carries out a disaster recovery every 30 minutes. We also ensure that clients keep their software versions up-to-date with all the new and enhanced features. The latest version of IndySoft has over 200 new features from the previous version and our road-map of new functions is bursting. It’s difficult to choose which to prioritise. • There is no restriction to what equipment you can store, calibrate or service with Indysoft’s software. Electrical, force, pressure, torque, dimensional, temperature, etc. You can create your own test points or embed MS Excel or MS Word documents and integrate with outside programs like Fluke, MetCal etc. • On-site calibrations can be performed with our stand alone systems and tablet computers and you can synchronise the updates back to the main server. • Automated alert reports and equipment calibration or maintenance due reminders can be automatically emailed to clients/colleagues whenever you choose. • The system has a comprehensive report builder to allow you to create automated reports, generate certificates, stickers, work orders, delivery notes, invoices, cal-due and service due reminders – in fact anything ‘branded’ that your business would need. • Allow internet access for historical certificate retrieval for your customers with our DataView module. Other modules include Trend Analysis, Uncertainty Calculations and Fluke MetCal Import Utility. You can also perform MSA studies like Stability, R&R, Linearity, Attribute, Bias and get Historical Charting on practically any scenario. • In addition, IndySoft also supports barcode scanning and RFI tracking. IndySoft, a BMTA member, is recognised as supplying the best ‘commercially available’ enterprise-wide range of gauge management, instrument calibration software and tool management software tools on the market today. This is largely due to their recognition of compliance with AS9100, QS9000, TS16949, ISO9000, FDA 21CFR Part 11 and ISO17025 – to name just a few.COMPANY PROFILE INDYSOFT bmta.co.uk Jake Bishop serves as Managing Director for two software companies and has been selling both software and metrology instruments into global industries concerned with Quality and Compliance for over 25 years. He graduated from Plymouth University with a BA degree and has used his leadership and sales experience to bring new cutting-edge concepts and products to market by strategising innovative sales and marketing initiatives. His work takes him all over the world where he makes board-level presentations. Technically competent, he is knowledgeable about quality control and improving processes. He is also a board member and the President of the GTMA (Gauge and Tool Makers Association), serves as a board trustee for The Tooling Trust, is a non-executive director of Treecom, the Managing Director of Hodi Hodi Safaris and serves as a town councillor in his hometown of Ampthill where he is the current Chairman of the Planning and Highways Committee and is on the council’s Executive Steering Group. JAKE BISHOP MANAGING DIRECTOR, INDYSOFTNext >