Advanced Electric Machines (AEM) worked with Made Smarter Adoption North East to adapt its manufacturing data capture process from manual spreadsheets to an integrated and automated Manufacturing Execution System (MES) that does everything from process monitoring to product and component traceability. The new solution provides real time access to data which has resulted in higher productivity across the shop floor.

Advanced Electric Machines (AEM) is an internationally recognised designer and manufacturer of electric motors and powertrain systems. Its mission is to design and build the most sustainable electric motors on the planet, supplying them around the globe from its facilities in Washington, Sunderland.

Why did you decide to sign up to take part in Made Smarter Adoption North East?

As a relatively small/young business it’s important for us to make sure we leverage the local and national networks set up to support growing SMEs. Both the North East Automotive Alliance (NEAA) and the North East Local Enterprise Partnership (North East LEP) suggested AEM should sign up to the Made Smarter Adoption North East programme as technical support and funding options were available for businesses like ours.

Prior to joining the programme, did you use digital technology within your business to improve efficiencies and productivity?

AEM is very focussed on the use of digital technology within the business. As we continue to scale up our production, we are seeking to adopt more digital technology and this was one of the main reasons behind joining Made Smarter Adoption North East as the available funding would help us accelerate our plans.

What were some the barriers to introducing digital technology within your business?

We are lucky at AEM as we have an experienced team who have worked at companies who were early adopters and technology leaders in digitalisation, so they know what ‘success’ looks like. Being an SME, the main barrier we have faced hasn’t been the know-how, but the capital investment we have been able to commit at each stage of our plans for the vision we have for the business.

What have you enjoyed most about taking part in Made Smarter Adoption North East?

When we enrolled, I hadn’t fully appreciated the concept of the workshop sessions. I found these to be a useful reminder of good practice; things we often forget about during the day-to-day running of a business. The networking was extremely useful and we took advantage of visiting other people on the programme to share lessons learned with them. 

What digital technology/solution have you introduced in your business as a result of the programme?

The phase one objective was to adapt our manufacturing data capture process from manual spreadsheet operations to an integrated MES process offering full automated component traceability, process attribute and variable data capture, with RFID pallet tracking around the finished assembly line.

The project involved the integration of additional PLC/HMI hardware to facilitate for the devices needed for data capture; such as barcode readers, operator HMI interfaces for recipe instructions, and quality critical measuring to allow for real time AI data processing and visualisation.

With the new infrastructure in place this would allow for a flexible production line and the introduction of further devices, such as electric tightening solutions including Desoutter/Atlas Copco tooling, ensuring pass/fail data can be displayed to the operator and captured by the PLC to be uploaded to the MES system.

With the support from Made Smarter Adoption North East, we have been able to procure the hardware required to implement phase one of the project and we are in the process of building the control panels and developing the software to interface all of this all together in readiness for phase two.

Process hardware has been launched online for in-line checks and is providing useful data showing us trends in product performance and compliance. Store to shopfloor traceability is almost complete and is due to go live in May. Without the support from Made Smarter Adoption North East we would not be as advanced with project timing.

How has the digital technology/solution improved your business?

The manual tracking of process data and lack of real time visibility about what is really happening on the shop floor leads to a lot of non-value-added activity. With the solutions we are introducing we remove the reliance of the operator to capture and manually track process data and streamline the operation, enabling us to have real time access through a shop floor dashboard of what is actually happening.

This enables us to react quicker if we see any deviations in the data and also enables us to get a higher level of productivity across the shop floor.

Why is it important for manufacturing businesses to adopt digital technology?

Not adopting digital technology because “we’ve always done it this way” is not a valid reason in my mind, but it is what you hear from people so many times.

The cost of digital technology is reducing, and it’s becoming easier to integrate as more of the systems are standardised. If a business isn’t looking at introducing digital technology, they are not just standing still; they’re actually going backwards.

At AEM our vision is have a fully integrated assembly solution embracing all the relevant digital technology that is right for our business. There are a lot of things on the market, but not getting carried away and focussing only on what you really need to successfully grow your business should help keep people on track for successful implementation.

Don’t over complicate what you try and do in the first instance making it harder. Remember, it’s all about being ‘made smarter’.

Why should other manufacturing businesses in the North East take part in Made Smarter Adoption North East?

If you don’t sign up, you’re really missing out. It’s a great opportunity to network with companies on the same journey as you, and the chance to sound others out on concerns and share experiences.

The financial support process is very straight forward if what you are applying for is part of your business development and growth plans. The temptation may be to make a project up for the sake of getting some funding, but if that project was never part of business plan, ask yourself, is this seriously something we have the resources to deliver.

The workshops are a useful reminder (or nice introduction) and provide insight to help focus you on the tasks in hand to successfully introduce digital technology into your business.

To find out more about Advanced Electric Machines (AEM), visit advancedelectricmachines.com.

Businesses in the North East Combined Authority (Durham, Gateshead, Newcastle upon Tyne, Northumberland, North Tyneside, South Tyneside and Sunderland) can find out more about Made Smarter Adoption North East and sign up to take part here.

Businesses in the Tees Valley Combined Authority area (Darlington, Hartlepool, Middlesbrough, Stockton-on-Tees, Redcar and Cleveland) can find out more about Made Smarter Adoption North East and sign up to take part by visiting www.teesvalleybusiness.com.

About Made Smarter Adoption North East

Made Smarter Adoption North East is a fully-funded business support programme that helps manufacturers in the region increase profits, improve efficiency and grow by investing in digital technology. Grants are available to help eligible businesses introduce new digital solutions that save time and money.

Backed by world-renowned businesses and UK government, Made Smarter Adoption North East aims to drive growth in UK manufacturing by improving the development and adoption of emerging technologies across the sector.

The North East Growth Hub and Tees Valley Business are working with Made Smarter to deliver Made Smarter Adoption North East in the North East Combined Authority and Tees Valley Combined Authority areas.