UKTIN: How Advanced Connectivity can Transform Manufacturing

Dr Aparajithan Sivanathan (Siva), Chair of the UKTIN Manufacturing Expert Working Group, and Head of Digital Technology at the University of Sheffield's Advanced Manufacturing Research Centre, provides insight into how advanced connectivity can help revolutionise today’s manufacturing industry.

An estimated 60% of UK engineers are over the age of 50, meaning the manufacturing sector is likely to face a dramatic drop off in technical knowledge over the next 10-15 years. This makes next-level automation and the connectivity needed to enable it, vital for the future of the industry.

Here, Siva provides insight into how the sector can be transformed through advanced connectivity.

Tell us a bit about yourself and your role

I lead UKTIN’s Manufacturing Expert Working Group, which considers key opportunities to capitalise on the benefits of advanced connectivity across the UK manufacturing industry.

I am the head of digital technologies at the advanced manufacturing research centre, leading the advanced connectivity theme, including major DSIT projects such as 5GFoF and FoFoRAN.

For those unfamiliar with UKTIN, what does it do?

The UK Telecoms Innovation Network (UKTIN) is the innovation network for the UK telecoms sector bringing together industry, government stakeholders and academia to catalyse R&D investment, cooperation and commercialisation.

Formed in 2022, UKTIN is delivered by a consortium of four partners - Cambridge Wireless, Catapult Digital, University of Bristol and WM5G and supported by the UK Government.

Why is advanced connectivity so important to manufacturing today?

Advanced connectivity, particularly solutions like 4G and 5G, is critical to modern manufacturing because it enables a high level of automation, greater agility, real-time data analysis and collaboration across complex, digitally connected production environments. 

The manufacturing industry is undergoing a transformation into Industry 4.0, which emphasises smart factories, intelligent machines and data-driven decision-making. 

This is particularly important in today's environment, where more than ever manufacturers are under constant pressure from shrinking margins and in some instances, rising demands, to boost factory efficiency while enhancing safety and security.

The low latency and high speed of advanced connectivity solutions are pivotal in driving this transformation.

Can you tell us how 5G can help futureproof manufacturing?

The higher bandwidth and low latency of 5G creates the opportunity to manage and analyse large amounts of data in real-time. 5G can be used to connect goods, assets, the manufacturing line and even the factory as a whole, to AI tools in the cloud. This allows for less downtime, fewer ‘lost’ assets and greater productivity.

Be it tracking and monitoring assets and supplies, moving to a predictive maintenance model, linking bespoke customer requests to a dynamic supply chain or having the flexibility to easily reconfigure production lines, 5G enables a level of insight and control not yet seen. Real-time, high-quality images, video and data can also be shared with AI and machine learning systems optimising the output of your factory, improving efficiency, quality control and reducing waste.

What role are digital twins playing in today’s UK manufacturing industry?

Creating digital representations of physical equipment and processes for use in visualisation, modelling and control - known as digital twins - is a key part of the future factory. 

Having high speed, reliable connectivity allows for the creation of live digital twins, to digitally replicate the manufacturing environment. This enables more thorough, accurate and rapid testing in a virtual dimension before production hits the factory floor, minimising the need for downtime, disruption or costly mistakes.

Processes can also be analysed in greater detail and maximised for both the efficiency and sustainability of the factory floor. The improved speed, volume and reliability of 5G allows for comprehensive digital twins, to run ever more complex scenarios. All of which, for manufacturers, means accelerated transformation.

Can you give us an example of how 5G is improving manufacturing?

The 5G Factory of the Future project underpinned by the BAE Systems's Tempest Future Combat Air Systems Programme- which used data from 5G-connected sensors to capture, monitor and gain insights into the changing conditions impacting the factory environment - is a great example of how advanced connectivity is being leveraged to improve UK manufacturing. 

The project - which developed five use cases for 5G in manufacturing - included data from within the factory such as temperature, humidity, air pressure, but also external inputs such as tides and lunar cycles. The project demonstrated real time closed loop control of CNC machines, virtual PLCs and mobile robots.

The project estimated 5-10% improved machine utilisation, 10-15% reduction in energy usage and 20% reduction in maintenance time, arising from performance optimisation and enhanced resource utilisation, demonstrating how 5G can support UK manufacturers on their journey to a smart, productive and sustainable future.

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