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
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
Charles Darwin – ‘Survival of the fittest’
Those that survive are those best adapted for their environment
Thank [email protected]
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