Made in the Midlands recently hosted an engaging virtual breakout session on the topic of "Upgrading Factory Systems," focusing on how companies are addressing the challenges of modernising legacy systems and preparing for the future of manufacturing. The session brought together a diverse group of professionals from across the manufacturing sector to discuss strategies, barriers, and opportunities for upgrading factory systems to ensure a more efficient and data-driven future.
Participants:
- Carol McDonald – McLar
- Iain Fisher – Mattair
- Jacqueline Watkins – Hyfore
- James Miller – LK Metrology
- Roy Taylor – Malthouse Engineering
- Simon Dunn – Pryor Marking
- Tom Harris – Wavenet
- Vrinda Gupta – Powdertech Surface Treatments
- James Clayton – Tiny Tablet
Key Discussion Topics:
1. Legacy Systems: Pros, Cons, and Common Pain Points
The discussion began by acknowledging the widespread use of legacy systems in many factories, with participants sharing their experiences of both the benefits and challenges these systems bring.
Carol McDonald from McLar highlighted the mix of old and new equipment in their operations. The decision of where to invest next, especially when it comes to improving manufacturing data knowledge, is a significant challenge for many companies. Balancing legacy equipment with new technologies can be daunting, as companies must decide whether to retrofit or replace existing systems entirely.
Roy Taylor of Malthouse Engineering also touched on the limitations of older systems, particularly the inefficiencies, maintenance issues, and downtime they can create. He emphasised the importance of competent staff in driving the transition and pointed out that his company is working with universities to help bridge the skills gap.
Iain Fisher from Mattair discussed the issue of aging systems in the ventilation industry. Many companies are looking to replace older systems, but newer technology often comes with high costs. Instead, firms are seeking ways to improve legacy systems, such as upgrading to more energy-efficient equipment like EC fans.
2. Practical Approaches to Retrofitting & Upgrading
As the conversation moved toward retrofitting and upgrading, several participants shared their insights into practical approaches. Simon Dunn from Pryor Marking shared how their business is transitioning towards digital transformation. The company’s need for better systems to track and identify manufacturing process events—such as productivity metrics, rework, and quality control—has driven their push for more modernised equipment and software.
James Miller from LK Metrology also discussed automation and the need for inline systems, highlighting the gap in the UK’s manufacturing sector when it comes to automation. He pointed out that while the UK ranks 7th globally in manufacturing, it lags at 23rd in automation. Despite recruitment and capital constraints, James advocates for retrofitting where possible, especially as some legacy systems are simply too outdated to modernise effectively.
Jacqueline Watkins from Hyfore noted that many engineers in their sector are accustomed to the systems they know and often fear change, which can be a barrier to modernisation. She pointed out that data is only valuable if it's input correctly, emphasising the need for accurate, up-to-date information in the manufacturing process.
3. Barriers to Upgrading: Cost, Training, and Employee Buy-In
One of the key barriers discussed was the cost of upgrading systems, particularly when it comes to replacing expensive equipment. Many participants noted that the initial outlay for new technologies can be prohibitive, particularly for small- and medium-sized enterprises (SMEs).
James Clayton from Tiny Tablet discussed how small upgrades, like using interactive screens to share information across the factory, can be a quick win for businesses looking to modernise without huge investments. By moving away from paper systems and using real-time data sharing, companies can achieve immediate benefits.
Training and employee buy-in were also recognised as significant hurdles in the digital transformation journey. As Roy Taylor mentioned, it’s crucial to have staff who are capable and open to change, and his company’s partnership with universities is part of a larger strategy to equip the workforce with the necessary skills to drive future factory upgrades. Dolores also emphasised that companies can be “data-rich but knowledge-poor” and that reaching out to initiatives like Made Smarter can help businesses navigate the digital landscape effectively.
4. The Future: Scaling Up and What’s Next
Looking to the future, the conversation turned to the potential for scaling up and what’s next for upgrading factory systems. Dolores highlighted the importance of starting small and focusing on quick wins to build momentum. Breaking down larger projects into manageable tasks helps reduce the feeling of being overwhelmed, allowing businesses to make steady progress without being deterred by the size of the undertaking.
Tom Harris from Wavenet emphasised that the future of factory systems lies in connectivity—integrating IoT sensors and ensuring that all equipment is connected to a centralised data system. The ability to monitor, collect, and analyse data in real-time is crucial for improving efficiency and productivity in the long term and then crucially; protect it as these new systems are likely to subject to heightened risk of cyber attack.
Key Takeaways
- Legacy systems often come with a mix of pros and cons, including inefficiencies, downtime, and maintenance challenges, but they can still play a role if approached strategically.
- Practical retrofitting is a viable option for many businesses, but it requires careful planning and investment in sensors, automation, and data integrity to make older equipment compatible with modern technologies.
- Barriers like cost, training, and employee buy-in must be addressed, with an emphasis on creating a culture that embraces change and new technologies.
- The future of factory upgrades will likely involve scaling up digital transformation initiatives, focusing on IoT, automation, and real-time data analytics to drive productivity and efficiency gains.
The session concluded with a strong call to action: businesses should not be discouraged by the size of the challenge ahead. Starting small, focusing on small wins, and seeking external support, such as roadmaps from Made Smarter, can help companies build momentum toward a smarter, more connected future