Welcome to the October issue of MEPCA magazine. The event season is very much upon us, as demonstrated in our Cover Story, which delves into what attendees can expect at LiftEx 2025, the lifting industry’s premier event. You will also discover three other unmissable shows in our Events Preview section.
Our focus section returns to Digitisation this month. While it may not sit well with everyone, we’ve used ‘Digitisation’ to encompass digitisation, digitalisation and digital transformation. Why? Because digitisation is where it all starts; the transformation of physical and analogue data into a digital format. This treatment of information in turn enables businesses to employ digital technologies to improve processes – digitalisation in short – and taking the next step to strategically leverage this technology across an organisation is better known as digital transformation, and now AI is shaping the industry’s digital pathway of the future.
AI was also the topic of a recent Westminster Employment Forum I attended, which addressed the divisive impact of AI on employment. Turn to the Digitisation section for my report on this illuminating discussion. Also included in this section, we explore how B2B sales has been transformed by digitalisation with BigCommerce, Midlands3D looks at the digital transformation of the supply chain, SolutionsPT provides timely cyber resilience advice, and Zebra explains machine vision’s role in digitalisation.
This month, our Manufacturing Champion has dedicated their extensive knowledge of digital technologies to helping manufacturers optimise their processes. Now more than ever manufacturers need guidance to navigate this fast-developing field.
Oliver Batt, Editor
To subscribe to MEPCA visit our website www.mepca-engineering.com or scan the QR code. @Mepca-magazine
Murrelektronik Introduces Hybrid Safety Device for Ethernet/IP Applications
Murrelektronik, a leading provider of decentralised automation solutions, is expanding its popular MVK fusion fieldbus range with the launch of the MVK Fusion CIP Safety—a new hybrid I/O device designed specifically for Ethernet/IP applications. This addition brings the proven 3-in-1 functionality of discrete I/O, safety I/O, and IO-Link to automation systems that utilise the Common Industrial Protocol Safety (CIP Safety) standard.
Built for real-time safety
CIP Safety is a certified extension of the widely used CIP protocol (IEC 61508) that enables the safe transmission of data in real time— without the need for separate safety networks. The new MVK
Fusion CIP Safety device helps engineers easily integrate safety into both new and existing Ethernet/IP systems.
Compact, rugged and easy to configure
The device features robust M12 L-coded power connectors that offer a high current capacity in a compact form factor. Designed for use in harsh environments, the MVK Fusion CIP Safety is IP67-rated and features a fully encapsulated metal housing, resistant to shock, vibration, and temperatures from -22°F to +140°F (-30°C to +60°C).
Flexible output options
The safety output on Port X3 provides unmatched flexibility. It can be configured as two sourcing outputs, one bipolar output, or a combination of
both. Each port offers channel-specific customisation to suit a variety of application needs.
Advanced diagnostics for reduced downtime
MVK Fusion CIP Safety provides comprehensive diagnostics by continuously monitoring each channel for conditions such as overload, short circuits, and cable breaks, minimising unplanned downtime.
A seamless fit for ethernet/IP ecosystems
The MVK Fusion CIP Safety joins Murrelektronik’s expanding Ethernet/IP product family, which includes the MVK Pro IO-Link Master and high-performance managed switches—providing customers with a complete, future-ready solution for industrial automation.
murrelektronik.co.uk
Akona Process Solutions Set to Exhibit at Pack Expo Las Vegas 2025
Akona Process Solutions will exhibit at PACK EXPO Las Vegas 2025, taking place September 29 - October 1 at the Las Vegas Convention Center. Located at booth N-7402 in the North Hall, Akona will unveil its all new US stand, bringing together its full portfolio of processing and material handling equipment brands under one identity for the first time.
As a regular Pack Expo exhibitor, Akona is reinforcing its presence by showcasing Cablevey, Kason, Marion and Spiroflow, alongside Automation by Akona. Together these brands demonstrate Akona’s ability to provide complete, end-to-end system solutions across mixing, blending, sifting, screening, conveying and bulk material handling.
The stand will showcase a functioning Cablevey conveyor unit, a horizontal fluidized mixer and a large display screen featuring a new full system animation.
The exhibition follows soon after Akona’s new website launch, which offers a detailed view of the company’s expanded portfolio. The site showcases Akona’s shift from four leading brands into a unified solutions partner, making it easier for customers to explore technologies, system capabilities and application expertise all in one place.
Clear navigation, mobile-friendly design and detailed product information, including 3D models and solution overviews, provide visitors with an accessible way to understand how Akona can support their process needs.
Ryan Long, North American sales director at Akona Process Solutions, said: “Pack
Expo provides a platform to show how Akona supports customers with integrated solutions. By uniting our brands under a single name, we can demonstrate the value of working with one partner for process challenges. Our new website and revamped stand both reflect that commitment, bringing together expertise, capability and customer focus.”
akonasolutions.com
Digital Transformation in Manufacturing
Steve Adams, CEO of Lineview, considers how digital transformation and manufacturing intelligence can alleviate the present pressures facing the manufacturing sector.
Manufacturing inefficiencies are costing UK businesses significantly. The sector is facing the perfect storm of critical challenges; intense pressure to reduce costs, urgent demand to improve efficiencies, and investor attention on improving revenues.
Fortunately, accelerated digital transformation is helping the industry adapt to these shifting demands, whilst manufacturing intelligence – facilitated by artificial intelligence (AI) – has become a key enabler in running agile and productive production lines.
Deploying AI capabilities does far more than benefit the performance of a line, of course.
Such intelligence helps manufacturers identify and address subtle but important changes in machine behaviour, for example, before they become business critical problems. To truly capitalise on AI-ready capabilities, you must first ensure a strong data foundation is in place. Every machine has a standard performance pattern, a digital fingerprint, that reflects how it runs when it is operating normally. If a packer runs with a mean time between failure (MTBF) of 45 minutes that drops to 30 minutes, it indicates something has changed. Noticing this before the point of failure is critical. Especially for continuous-flow manufacturing operations, where manufacturers depend on tightly integrated lines with sequential, interdependent processes.
Having access to live and historical data with rapid analysis capabilities is a gamechanger in how manufacturers now conduct root cause analysis, alongside predictive analysis, to help factory workers understand what is happening in their production lines, even when comparing multiple sites and
geographies. Known as ‘Factory 2030’ – a manufacturing industry vision for the implementation of advanced technologies and processes – this way of working with intelligent data streams leans heavily into the integration of Industry 4.0 technologies – AI, machine learning, and IoT – to optimise production, reduce costs and improve overall efficiency.
To support this movement towards smart-factories we have invested substantially in our own software capabilities to deliver our new cloud platform – Lineview Navigator. Delivered in three modules, Monitor, Review and Analyse, the complete platform bridges the gap between data collection, analysis and execution as every data point is presented into contextualised, prioritised opportunities for improvement, managed via built-in workflows and real-time alerts. Intelligent API connections allow highly accurate line data to integrate across the digital network, and into ERP, SAP, maintenance & warehouse management systems, and it supports live feeds from energy monitoring or condition-based monitoring, meaning that customers can fully integrate the supply chain.
occurred & debating how to prevent it happening again. Now, using machine & production line DNA, we can transform manufacturing with data to look forward. This is a major shift in the paradigm, and we continue to advance our work here, looking at how AI can provide detailed context and recommendations based on historical and current performance levels, moving customers from reactive to proactive management. Embracing real-time AI technologies that can support cross-site collaboration, and deliver on productivity and sustainability metrics, also helps operators to agree benchmarks on what good looks like which can be invaluable in such a competitive sector.
Our customers are increasingly telling us how important a 360 degree insight is. Manufacturing has been operating in ‘rear view mirror’ mode for many decades, historically analysing why a problem
Ultimately, the manufacturers combining people, data and technology will be the ones that achieve agile, smart, operations the fastest.
lineview.com/en/
Global Lessons for UK Manufacturing
As the UK falls behind its global competitors in innovation and productivity, Verity Davidge, Policy Director at Make UK, warns that it must increase uptake of automation, robotics and AI to compete, and doing so will mean upskilling the British workforce.
British manufacturing companies have been lagging behind international competitors in the use of automation over the last two decades, with manufacturers falling dramatically down the global league tables. Our use of robotics and AI systems is poor, with training of people in relevant digital skills to take advantage of the innovation tech well below what is needed to catch up.
A new report, Making it Smarter: Global lessons for Accelerating Automation and Digital Adoption in UK Manufacturing1, launched by Make UK and Sage reveals that nearly half of British manufacturers identify a lack of technical skills as the biggest hurdle to improving their use of innovative advanced technologies. Projects embarked on often stall after implementation stage because companies cannot find the support needed. Countries where all SME innovation funding and advice is held under one easy-to-access ‘umbrella hub’ have dramatically higher success rates.
The Government’s recent Industrial Strategy sets out how it will create a digitally literate workforce by 2035, but we simply can’t wait ten years for this to happen. Make UK is calling on Government to embed targeted funding for digital skills needed in manufacturing and engineering to accompany the existing £100m already set aside for engineering skills.
For decades, South Korea has been undergoing a successful automation drive to transition from legacy production methods to advanced digitalised factories. It has stuck religiously to a single strategy, concentrating on education, infrastructure and innovation. The Government provides SMEs with bespoke incentives, offering easy to access R&D tax incentives of 30% for companies investing in semiconductor facilities, and
broader tax credits guaranteed to 2029 and beyond. This certainty and confidence has led to South Korea turning into a global leader in the production of semiconductors and other advanced technologies.
The South Korean Government also saw the need to make education work for industry –providing the employees to power the technologies. It committed to training 40,000 people to operate fully automated production systems and there are now no skills shortages in technical and digital innovation. The rewards are high; firms adopting smart technologies see a 25% increase in productivity and a 27% drop in defects.
Singapore underwent a similar transformation and is now a global leader in high-value advanced manufacturing, concentrating on the lucrative semiconductor market, precision engineering, pharmaceuticals and clean energy.
Singapore’s pro-innovation environment delivers some of the most generous R&D tax incentives in the world, where companies can claim up to 400% tax deductions on local R&D or opt for a 20% cash payout.
The incentives are embedded in a long-term industrial policy, giving SMEs and start-ups greater cashflow certainty, and the ability to grow to their full potential.
Germany has stayed top of the international performance leagues consistently over the last decade. It’s success is largely driven by embedding research institutions into local industry, with a particular focus on SMEs. Overall, Germany’s successful approach blends SME-only tax relief, sector-specific research and regional accessible digital support.
With a population no larger than London’s, Switzerland delivers a manufacturing output of around £150 billion — astonishingly close to the UK’s £217 billion. This remarkable productivity stems from a national strategy that prioritises advanced technologies, SME competitiveness and long-term innovation. The Swiss Innovation Agency typically funds up to 50% of eligible project costs for SMEs, while larger firms only qualify if they partner with smaller ones.
If UK Manufacturing is to improve its competitiveness then this shortfall in the use of automation must be addressed. makeuk.org
Dave Atkinson, UK Head of Manufacturing, SME & Mid Corporates at Lloyds, considers how a new era for UK defence presents a growth opportunity for manufacturing SMEs.
The UK’s new Industrial Strategy and Strategic Defence Review reflect a world where a growing focus on national security will direct ever more investment into defence supply chains. As global threats continue to evolve, these initiatives outline the nation’s ambition to build a more integrated, innovative and resilient defence sector. And a strong defence sector is not only a matter of national security; it can also be a key driver of economic growth.
Central to the UK’s strategy is a renewed initiative to reform and reshore defence procurement, which presents an opportunity for manufacturers to rise to this challenge and bid for new contracts. It’s a move that the Prime Minister has said will create a ‘defence dividend’, creating highly-skilled jobs, security and rebuilding the nation’s industrial base.
As one of Britain’s biggest banks, we know that we have a role to play here too, backing UK manufacturers as they diversify, innovate and invest for the future.
Safer and stronger
Manufacturers of all sizes must remain alert to the growing opportunity that this expanding market presents. Ministry of Defence (MOD) spending with industry already supports more than 200,000 jobs across the UK, with nearly 70% of that investment being directed outside London and the South East1
The UK’s Industrial Strategy highlights defence and advanced manufacturing as being among eight sectors with the greatest growth potential over the next decade, with an ambition to make the UK a defence industrial superpower2
The Prime Minister has now made a commitment to increase spending on
national security from 2.3% to 5% of GDP by a target date of 2035, including 3.5% for core defence and 1.5% for resilience and security3. In today’s terms, that totals more than £140 billion a year4. And this comes alongside spending targets that aim to ensure SMEs get a bigger share of that spend, which has historically been the preserve of larger contractors.
Boosting the defence industry’s ecosystem in this way can also help improve productivity, upskill workers, increase exports and drive regional equality.
Accessing opportunity
To that end, Lloyds has specialist teams to provide the financial solutions that enable manufacturers to develop new capabilities, expand capacity and deliver on defence contracts. We have built strong partnerships with industry bodies including MTC (Manufacturing Technology Centre) and Make UK, which help manufacturers unlock access to defence suppliers and SMEs.
Supplying the MOD and its Tier One suppliers means meeting security, quality and compliance standards that can be far more rigorous than those demanded by other industries. But defence contracts can also open the door to funding streams that support firms’ innovation and develop new skills, while also diversifying their revenue streams and boosting their export potential. It all represents a new era for the defence sector and a fresh opportunity for SMEs to play an ongoing and important role in the UK’s national security, while also generating economic growth.
See how Lloyds is supporting UK manufacturers to innovate, grow, and lead at:
MEPCA are delighted to introduce Dr Katharina Roettger, Principal Scientist at CPI, a pioneering social enterprise dedicated to building innovation ecosystems that connect academia, industry and government. Kat applies her expertise in digital technologies to process improvement, assisting manufacturers, of all sizes, to scale innovative projects.
After completing her at PhD at Kiel University (CAU), Germany, Kat re-located to the UK to continue her postdoctoral research on molecular dynamics, spectroscopy, and time-resolved spectroscopy. Seeking a break from academia and wishing to direct her expertise away from more fundamental research to industrial research, Kat joined CPI in 2016.
“I wanted to see what industry is doing. That’s how I came to work at CPI, because [at] CPI, we’re a research and technology organisation and we sit between academia and industry,” Kat explained to MEPCA’s editor, Oliver Batt. This positioning enables CPI to help companies navigate through that difficult gulf between ideas and commercialisation.
Her initial project for CPI took her in a refreshing new direction: “I led the development of a digitally enabled pilot plant for liquid mixing, which was very different from my postdoc.”
This project involved developing digital capabilities for this small pilot plant, including process analytic technologies, to gain valuable insights into the manufacturing process, measuring things like particle size and viscosity. They collected this data to provide real time insight into liquid mixing processes.
“That was really interesting and I learned a lot in that time about both digital infrastructure, data collection, analytical instruments, and so on.”
However, it was the challenges that could not be solved that held as much fascination, particularly those related to how prohibitive the cost of measurement technologies is
to smaller companies or companies in low margin industries. This led her to looking at alternative solutions; an area she has continued to focus on.
“If you want to measure viscosity, for example, you can either buy an instrument that can do that in line or you could build something which is called [a] soft sensor, where you infer viscosity based on other measurements, like pressure sensors, for example.”
Soft sensors are a non-invasive, digital approach to sensing technology that takes
data already held by a manufacturer and uses digital technologies to infer further data from; this forms the basis of predictive modelling, which provides information on what a process will look like over time.
It’s often the case that manufacturers don’t believe that they hold much data, or that the data they hold is unusable, but Kat insists there is nearly always something that can be done with that data, if the right approach is taken. Rather than asking a company what data they have, or offering to build them an AI tool, she wants to
understand what their challenges are, as the right approach is “problem-led and not solution-led.”
Referring to research released by the RAND Corporation, Kat explained that among key reasons for digital technology and AI adoption project failure is that these organisations “look at solutions first and don’t define the problem properly. And that is how a lot of these projects fall over because you need to know what you want to know first before you start looking for a solution.”
When asked whether the current hyperfocus on AI as a solve-all technology was perhaps overshadowing other equally important technologies, she agreed that, to an extent, it did. Taking predictive modelling as an example:
“We are not yet at a place where you could just feed all the data into an AI and it will give you the answer […] a lot of it is still, in a way, a very manual process where you need to understand what the process is, you need to understand what the challenges are.
“That’s something that sits with the operators, with the technical people on the
MANUFACTURING CHAMPION
plant; they know everything there is to know. No AI has that knowledge, at the moment.”
AI is of course important, and CPI utilise AI and machine learning, but returning to her earlier point on challenges before solutions, she said, “It’s about process optimisation, not about the techniques that we use to solve the challenges.”
At CPI, Kat has dedicated her expertise to helping manufacturers find digital solutions to their challenges, and she finds it most satisfying to work on projects with smaller companies – helping those technical operators to improve processes – and seeing the difference more directly.
An example that stood out for her was Therma-Chem, a family-run business based in Glasgow that makes cleaning products for industrial boilers, such as those found in the heating systems at oil refineries. CPI started working with them circa five years ago,
looking at how they analyse and use their data, and upskilling their team.
“What’s really, really nice to see is that they really value what we are doing. They want to change the way they do their business by adding more digital services to their business model. And it’s just a wonderful collaboration. They are very, very innovative. If we had more companies like that in the UK, I think it would be great.”
CPI’s continued efforts were recognised in the Industrial Strategy, which referenced the Advanced Materials Battery Industrialisation Centre (AMBIC) in Sedgefield, aimed at enabling the development of new battery materials and accelerating the clean energy transition. Further details of this and other innovative projects CPI have been involved in can be found on its website.
uk-cpi.com
“It’s about process optimisation, not about the techniques that we use to solve the challenges,”
Dr Katharina Roettger, Principal Scientist at CPI.
The
heating and cooling
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Find Lifting Answers at LiftEx 2025
Celebrating its 20th year at the Exhibition Centre Liverpool on 18 & 19 November, LiftEx is a must visit for anybody involved with procuring or using services and lifting equipment to support production and assembly lines in plants and factories around the world.
This year’s event offers the perfect opportunity for finding lifting solutions while also networking with the global Lifting Industry.
The annual flagship event of the Lifting Equipment Engineers Association (LEEA), the leading global representative body for all those involved in the Lifting Industry worldwide, is supported by RiConnect, a provider of cloud-based Software as a Service (SaaS), as Headline Sponsor, along with sponsors Yoke and Hoist. LiftEx 2025 is primed to build on the success of last year’s event, held in London, which was the largest and most successful ever and welcomed a record number of end user visitors from multiple industries.
Safe practice is vital in busy manufacturing and production facilities. Those responsible for procuring lifting equipment and services in these operations will need to fully understand the risks, consequences and legal obligations, as well as filter good practice from the bad.
Visitors to LiftEx 2025 will find ways
to improve safety and best practice with advice from industry experts throughout the exhibition, as well as the LEEA team, who will share their expertise and industry insights.
Thought leadership
To boost this important aspect of LiftEx, a new Thought Leadership Conference, which is also free to attend, will take place on Day 1 of the exhibition. Speakers lined up include Tim Battersby, Technical Sales Manager at RiConnect, who will give an ‘Introduction to the Digital Product Passport’ Attendees will become familiar with the objectives of the Digital Product Passport (DPP), understand what we know so far on the DPP, and learn what we can do now to prepare for future digitalisation requirements.
Anton van der Zalm, Vice President Corporate Research & Development at Van Beest BV, will give a presentation titled: ‘From Surface to Seabed and Back: Innovations in Load Release and Retrieval’. As subsea operations become more complex and efficiency-driven, the technology behind load release and retrieval continues to evolve. This session
explores the latest innovations in subsea installation equipment, with a focus on smarter, safer techniques for deploying and recovering loads from the seabed. It will examine advancements in ROV-operated shackles and hooks, and how these are reshaping industry standards for remote handling, reducing risk and improving operational uptime. Drawing from field experience, the session will offer practical insights into how new approaches to load management—from surface to seabed and back—are enhancing subsea project execution. Ideal for professionals involved in offshore operations, marine engineering and subsea logistics, this talk balances technical education with real-world application.
Adeoluwa Bamgbade, Temporary Works Coordinator at SCS Railways, will examine ‘Tunnel Boring Machine Shield Extraction on HS2 London Tunnels’ This session will share how SCS engineered bespoke lifting solutions, applied advanced planning tools, and ensured safety throughout complex operations. Delegates will learn practical approaches to heavy lift design, risk management and innovative techniques that can be applied to similarly demanding projects.
Ollie Brown, Economist at GlobalData Plc, will discuss ‘Vertical Construction amid Evolving International Trade’. This session will cover market trends, new project developments and maritime trade dynamics and implications.
End user seminars
There will also be an End User Seminar taking place on Day 2 of LiftEx on Wednesday 19 November. The programme features Andy Cartwright, Technical Manager at Mentor, looking at ‘Slinging vs Lashing: The Critical Difference’ Learn why choosing the correct method for load securement is essential for safety and compliance. This session will highlight the practical and regulatory differences between slinging and lashing, helping end users avoid common pitfalls and reduce risk on site.
Daniel Jennett, HSE Manager/HSE Lead at Sheffield Forgemasters, will present on ‘Beyond the Surface: Use of Emerging Technologies for Advanced Rope Inspection’ to explore how advanced inspection technologies are transforming the way ropes are assessed and maintained. This session will demonstrate how new tools and methods provide deeper, more accurate information, improving reliability and
extending equipment life.
Kurt Thomsen, Crane and Lifting Expert from RelyOn, will discuss the ‘Advancement of Training and Skills in the Lifting Industry’ for attendees to discover how innovative training programmes and practical expertise are shaping the future of the lifting industry. This session will explore new approaches to workforce development, helping end users build safer, more capable teams equipped to meet today’s operational challenges.
Jordan Weston, Commercial Manager Services EMEIA at Bekaert, will deliver a presentation on ‘Beyond the Surface: Use of Emerging Technologies for Advanced Rope Inspection’. Join the follow-up session on rope inspection to gain further insights into emerging technologies and their real-world applications. This discussion will offer additional perspectives to strengthen inspection practices and improve operational safety.
Exhibitors
In addition to the conference sessions, the show floor will be packed across both days with over 100 brands demonstrating innovations to improve productivity, efficiency and safety. These new products and services offer crucial solutions for achieving successful manufacturing.
A broad array of lifting equipment will be exhibited by from AP Lifting Gear Company, Atlas Winch & Hoist Services, Cromox, Delta Hoisting Equipment, George Taylor Lifting Gear, GGR Group, Hird Ltd, Lifting Material Supplies, Liftket UK, Miller Weblift, Miller Weblift, Modulift, Reid Lifting, RHC Lifting, SGM Magnetics, Tiger Lifting, TTC Lifting, and Worldhoists. There will be
materials handling equipment on display from Aconda Industrial Carriers, Probst and engineering & manufacturing services from Gemmak Engineering, Wirop Industrial Co, and Worlifts.
Chains, ropes, slings, rigging and accessories will be shown by from Bekaert, CODIPRO, GIS – Lift Turn Move, Green Pin (Royal Van Beest), JDT, Marlow Ropes, pewag UK, Rope and Sling Specialists Ltd, RUD Chains, Sahm Splice, Talurit, William Hackett, and YOKE Industrial Corp.
There will be height safety equipment and services from Globestock Safety, Safehold, SafetyLiftinGear, SpanSet, and The Buddie System.
Visitors will find load monitoring equipment from Dynamic Load Monitoring (DLM), Load Monitoring Systems (LMS) and Red Rooster Lifting and IT solutions from CMCO (Columbus McKinnon), Core Inspection Software, coreRFID, IRUGASA (UK), Motion Software, Onix, Papertrail, RiConnect Inc, and Tele Radio. There will also be test machinery from Tensology.
Lifting and safety training can be found from Carl Stahl Evita, City of Bristol College, Elevation Training & Development and, of course, LEEA will have its usual prominent stand for visitors to meet and engage with the Association’s team for lifting advice, to learn about training and to hear about the many benefits of becoming a LEEA member.
With even more speakers and exhibitors to be confirmed, all of this means a visit to LiftEx 2025 in Liverpool offers the perfect chance to strengthen safety, compliance and efficiency in everyday lifting operations. Register now.
liftex25.eventreference.com
Employment and the Shadow of AI
Ai is here, and foremost amongst the concerns of workers in manufacturing is replacement. The question is whether that fear is justified. MEPCA’s editor attended the recent Westminster Employment Forum: The Future of AI in Employment to learn more about this divisive topic.
AI adoption has become synonymous with progress in the manufacturing sector, and beyond. Whether used in the form of the latest ERPs, intelligent CAD programs, or tools for predictive maintenance, AI-based technology is already proving its usefulness.
However, there currently exists a hyper-focus on AI in the media, treating it simultaneously as a solve-all solution and dangerously out of control technology. But is AI the seismic shift in industry that we’re being led to believe? And are the fears of widespread job replacement valid? Or, in both cases, are we overreacting and overreaching based on the information available?
It is with these questions in mind that I attended the Westminster Employment Forum policy conference: The future for AI in employment – priorities for policy, regulation and industry best practice.
The opening speaker, Professor Joanna Bryson, Professor of Ethics and Technology, Hertie School, Berlin, began the discussion by pointing out when we speak about robots or AI taking jobs we’re prescribing agency to them that they simply do not have; it is better to say that corporations will make decisions on how many people they hire. Jobs are, she pointed out, agreements between people.
How technology affects an industry, Bryson suggested, is not always as we might expect, using Geoff Linton, one of the founders of machine learning and Nobel Prize winner, as an example. In 2016, he asserted that people should stop training radiographers, in reference to the disruptive power of machine learning tools introduced in radiography. In reality, the demand for radiologists increased, with more clinics being able to house a radiographer.
“Ethical adoption requires clear governance, human oversight, transparency, especially when the investment is starting, [and] trust building with employees.”
Nina Gryf, Senior Policy Manager, Make UK.
Of course, it does not follow that technological advances mean more jobs, necessarily, but Bryson’s point is that it can do. The analogy Bryson used: software that doubled the efficacy of teachers could result in schools that were twice as good or half as many teachers (or a combination of the two). The difference, Bryson pointed out, “is a matter of policy. It’s normative.”
Reframing this in manufacturing and it’s the difference between a business being able to expand its operations, or reduce headcount and achieve the same output. AI
based tools could enable both; the choice is the manufacturer’s, unless policy mandates, prescriptively, the more ethical choice.
During the course of the conference, two illustrative comparisons stood out. The first, which was introduced by Professor Joanna Bryson and later echoed by several other speakers, was that of the industrial revolution. By no means a novel comparison given AI’s prominent role in ushering in industry 4.0., but it serves to show the importance being placed upon the technology.
The second comparison of note was first introduced by the chair Viscount Camrose, Shadow Minister, Department for Science, Innovation and Technology, when he likened the hype-cycle of AI with the dot-come bubble, which saw the unprecedented growth of investment in internet-related technologies before bursting in March 2000, resulting in a dramatic market crash. Camrose’s fear is that AI, as the current focus of trillions in investment, will lead to a similar crash. This is something we will return to later.
Before the second panel discussion, Trinh Tu, Managing Director of Public Affairs at Ipsos UK, shared research into public opinion of AI, which addressed important factors around AI adoption, including the impact on the job market, and the skills gap. Showing in particular that a lack of trust is proving to be a real barrier to adoption: 55% of people did not believe that AI would create more jobs than those that it replaced, with only 12% believing it would.
Trinh Tu: “And these anxieties really translate directly into the public’s distrust of AI’s benefits.”
Interestingly, Anglosphere countries, including the UK, are more nervous about AI adoption than other global demographics.
However, it did not follow that the UK is anti-innovation, as Tu explained, but rather it is concerned about the slow reaction of policy in comparison to AI development, with 60% believing that “UK government should adopt a cautious AI strategy to safeguard jobs and allow adaptation, even at the cost of global innovation pace.”
Tu concluded that to improve trust and therefore further AI adoption organisations should clearly explain the use cases for AI, including what task it is for, and why it is of benefit to that task, etc.
Following on from this broader view of AI adoption, Nina Gryf, Senior Policy Manager, Make UK, provided an industrial view point. Gryf acknowledged that the UK has several great research institutions developing innovative technologies, but referring to the report Future Factories Powered by AI1, Make UK surveyed 150 manufacturing companies and found that only 36% were using AI in their factories.
This comes despite the fact that over half of the companies using AI are already seeing improvements in efficiency, productivity and reducing operational costs. The reason for this reluctance, echoing the wider research undertaken by Ipsos UK, is one of
confidence in the safe use of AI.
Gryf illustrated how industry might combat this using the example of one of Make UK’s members who involved workers in the purchasing process of AI-powered robotics, enabling them “to be part of the decision making”, which proved to help adoption and alleviated fears of job-loss, reinforcing the notion that the workers were being upskilled rather than replaced.
Gryf: “Ethical adoption requires clear governance, human oversight, transparency, especially when the investment is starting, [and] trust building with employees.”
In addition to these points, which are crucial to building trust in AI amongst workers, the wider application of AI and views around return on investment are also important. As mentioned above, the current hype around AI has drawn comparisons to the dot-com crash of 2000.
John Chadfield, National Officer, Technology, Communication Workers Union, added weight to this comparison, making reference to both Klarna’s disastrous AI deployment and Meta potentially reducing its AI department.
“We’re also far enough into the AI hypecycle that longitudinal research is now available on a number of impact factors, and this includes MI TS report published last month, as stated 95% of organisations found zero returns despite enterprise investment.”
Chadfield went on to address some myths around AI before ending, controversially, on the notion that the main thing holding AI
back is neither adoption or data, but simply that it doesn’t work, and furthermore, what enterprises appear to be trying to solve with AI is the ‘problem’ of paying wages.
In the following discussions, Nina Gryf, commented that in manufacturing, there isn’t evidence of layoffs, as those described by Chadfield, as a result of the adoption AI and automation; instead the sector has a very different problem: over 50,000 vacancies that need filling, and a growing skills shortage.
In manufacturing, at least, investment in AI is less likely to be driven by the ‘hype-cycle’ of Wall Street investment, and more by practical concerns.
In the last panel, Dominic Lusardi, NonExecutive Director, Digital Thinkers, made a sobering point: that we should “demystify” AI; “It isn’t magic,” and he described it simply as a system of “pattern recognition running at speed over a zero latency network. That speed is extremely impressive, but it’s also a risk. Once an error is in the system, the A I will repeat it endlessly until a human steps in.”
While the long term benefit of AI and how it will impact industry and the job market remains uncertain – and divisive – what is certain is that it will lead to change, and how to manage that change and ensure it is utilised positively is with policy, transparency, and the involvement of those it will affect most.
Advancing in digitalisation without considering business continuity and disaster recovery as a vital step will hinder transformation efforts. To help address this, industrial cybersecurity specialist SolutionsPT shares 5 best practices for cyber resilience.
As we start another year, cybersecurity should be at the forefront of digital transformation plans, and for good reason. Statistics released in 20241 show a global increase of 25.7% in cyberattacks for manufacturing alone. The National Cyber Security Centre 2024 Annual Review2 states that the threat to the UK’s critical water, wastewater and energy infrastructure is ‘enduring and significant’.
These statistics prove the importance of prioritising cyber resilience across the broad spectrum of industrial sectors and strengthening defences alongside digitalisation progress to best maintain business continuity.
Where traditional cybersecurity primarily looks to prevent breaches, cyber resilience maintains core operations even during an active cyber-attack.
Data visibility = cyber resilience
Best practice for disaster recover involves putting a plan in place covering digital capabilities and data visibility. This plan will support consistent operations for industrial businesses of any size:
1. Risk assessment
While not new to industrial enterprises, risk assessments must be consistent and always evolving to meet new cyber threats. New vulnerabilities are found every day so repeating the same risk assessment won’t alert these to operators. Robust risk assessments must adapt to the constantly changing threat landscape, requiring active research from a dedicated team.
2. Asset Identification
Understanding your most critical asset and
their security posture is key to establishing the effort and controls that are necessary to provide cyber resilience. With the abundance of legacy assets, now in a highly connected world, makes defending these a challenging if not impossible task. Where protection is not possible or feasible, redundancy, isolation and recovery become more important than protection.
3. Redundancy and Segregation
Availability drives automation, protecting systems through segregation creates isolations zones between processes, allowing them to continue when others around them have been compromised. Critical systems should have built in redundancy at the hardware and software level to deliver availability during period of maintenance and unplanned downtime.
4. Automated threat detection and backups
Regular backups and redundant systems ensure critical data is not lost and can be quickly restored. These should already be part of any cybersecurity strategy. Adding advanced and automated threat detection will flag irregularities and send alerts to operators. Digital transformation uses data-driven insights to empower operators to make informed decisions, and a cyber resilience strategy must work the same way.
5. Skills/training
As cyber threats are always evolving, operators need the skills and knowledge to address them. Simultaneously, there is a growing skills gap within industry that includes those fundamental cyber skills.
Simple check box training exercise covering the basics of cyber security during employee onboarding will no longer suffice. Like all digital transformation capabilities, businesses that want to ensure cyber resilience should commit to continuous learning or seek a partner organisation with dedicated expertise to share the responsibility.
Each of these five best practices will prepare industrial businesses against cyber threats but rely on complete data visibility. Data visibility means that risk assessment, high availability, threat detection, and most importantly response is based on real-time information, only then can issues be solved before they escalate.
Cyber resilience should be the lead focus for cybersecurity efforts in 2025. With attacks increasing across all industrial sectors and of all sizes, all businesses are at risk. Cyber resilience ensures that even when an attack occurs, core operations can remain safe and stable while recovery is swift. One way to do this is choosing a complete industrial cybersecurity partner such as SolutionsPT that removes the complexity and fortifies operations in today’s industrial landscape. solutionspt.com 1https://www.statista.com/statistics/1315805/cyber-attackstop-industries-worldwide/ 2https://www.ncsc.gov.uk/pdfs/news/ncsc-warns-enduringsignificant-threat-to-uks-critical-infrastructure.pdf
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Smart Warehouses Driving US Industry
According to Dexory, the hidden engine powering the resurgence of America’s manufacturing sector is the smart warehouse. In this article, the leading robotics and AI logistics company identifies which digital technologies are helping to revolutionise America’s warehouse operations.
The revival of American manufacturing is making headlines, and for good reason. With growing emphasis on economic security, supply chain resilience, and domestic job creation, the U.S. is experiencing a manufacturing renaissance. But while much attention focuses on new factories and production lines, there’s a critical piece of infrastructure working behind the scenes that could make or break this industrial comeback: warehouses.
Today’s warehouses have evolved into intelligent, technology driven hubs that serve as a nervous system of modern manufacturing operations. As companies work to reshore production and scale up domestic manufacturing, the warehouses that support these operations must be equally sophisticated to ensure success.
Three technologies revolutionising warehouse operations:
1. Robotics: the productivity multiplier
Today’s robotic systems handle autonomous picking and packing, automated material handling and continuous inventory scanning, all while operating around the clock. For manufacturers, this translates into reduced labor dependency (crucial in today’s tight labor market), scalable operations that can grow with demand, and most importantly, continuous material flow that keeps production lines running.
2. Digital twins: the crystal ball for operations
Digital twin technology is revolutionising how warehouses plan and operate by creating virtual replicas of physical warehouse
environments. These digital models enable dynamic inventory management, simulation and optimisation of workflows, and predictive maintenance – all in real-time.
3. Data intelligence systems: the foundation of smart operations
The third pillar of smart warehouse operations is comprehensive data intelligence systems that combine AI, robotics and digital twin technologies to provide real-time visibility into every aspect of warehouse operations.
These systems deliver real-time inventory accuracy through continuous scanning of thousands of locations per hour, eliminating stock discrepancies that can halt production lines.
Real world impact: the numbers don’t lie
The theoretical benefits of smart warehouse technology are impressive, but the real world results are even more compelling. Recent case studies demonstrate the transformative impact these technologies can have on manufacturing operations.
DexoryView is at the heart of this transformation. The autonomous robots capture data across 10,000+ locations per hour, feeding into a digital twin platform that maintains 99.9% inventory accuracy and uncovers inefficiencies in real time. For manufacturers, this means fewer stockouts, smoother production flow, and the ability to make data driven decisions that protect uptime and improve resilience.
The synergistic effect: when technologies work together
While each technology delivers significant benefits individually, their true power emerges when they work together as an integrated ecosystem. Robotics gather data, digital twins simulate and optimise workflows, and AI systems make real-time adjustments – creating a closed loop system that continuously improves performance.
Building America’s manufacturing future
The resurgence of U.S. manufacturing isn’t just about building more factories; it’s about building smarter, more resilient supply chains that can compete globally while serving domestic needs. Warehouses powered by robotics, digital twins and intelligent inventory systems are central to this strategy.
The warehouse revolution is here, and it’s powering America’s manufacturing future, one smart decision at a time.
dexory.com/solutions
Keep production lines moving with precise, real-time stock insights
Modern manufacturing depends on warehouses maintaining accurate, real-time inventory data, enabling just in time production models, and rapidly adapting to supply chain disruptions.
Recent case studies demonstrate the transformative impact three main technologies can have on manufacturing operations:
1. Robotics: the productivity multiplier
2. Digital Twins: the crystal ball for operations
3. Data intelligence systems: the foundation of smart operations
DexoryView is at the heart of this transformation.
The Digital Shift in Manufacturing
The way companies buy and sell has shifted away from traditional B2B sales relationships in favour of seamless digital transactions. To remain competitive, B2B manufacturers must embrace ecommerce. Learn how even established manufacturers can achieve digital transformation with ease by adopting the right technology.
Manufacturers and processors have always been the backbone of industrial progress. But as global markets evolve and supply chains become more complex, the way companies buy and sell in B2B markets is changing. Procurement managers, distributors and industrial buyers expect the same seamless digital experiences they enjoy in consumer life – but with features adapted to the unique needs of B2B buyers.
For businesses across processing and manufacturing, this shift presents both a challenge and an opportunity. Those who adapt stand to gain efficiency and new market reach. Those who delay risk falling revenues.
The state of B2B: from catalogues to clicks
Traditionally, B2B commerce in manufacturing has relied on long sales cycles, paper catalogues and personal relationships. These methods delivered stability, but cannot keep up with the modern buyer’s needs. Today, research from Gartner1 shows that 75% of B2B buyers say they prefer digital self-service for researching and ordering products.
This preference is not just about convenience, but also allows customers to be more agile and productive in their own roles. Digital-first buyers demand:
• Real-time inventory visibility
• Transparent pricing and shipping costs
• 24/7 access to product information
• Seamless reordering and account management
Companies that still rely only on manual
processes are finding themselves at a disadvantage. By contrast, manufacturers who invest in ecommerce platforms gain both efficiency and the ability to expand internationally without proportionate increases in sales resources.
How buyer expectations are changing
Many industrial buyers are no longer comparing direct competitors; they are comparing the ordering experience to what they encounter with giants like Amazon. A procurement manager who can order office equipment with one click expects a similarly frictionless experience when ordering replacement valves or machine parts.
This phenomenon is reshaping manufacturing procurement. The new B2B
buyers expect speed, accuracy and ease. Companies that fail to adapt risk losing longstanding customers to competitors who can deliver a more modern digital storefront.
Getting online with confidence
Digital transformation doesn’t have to be as complex as it sounds. Platforms like BigCommerce – powered by parent brand Commerce – enable manufacturers to move online quickly while integrating with existing ERP, PIM and CRM systems. This allows businesses to start small, for example by digitising repeat orders, and then expand as they gain confidence.
Beyond simply going online, digital solutions can also support the diversification of sales channels. With Feedonomics – also
part of the Commerce solution stack –manufacturers can manage and syndicate product data across marketplaces, search engines and industry platforms. This ensures products are discoverable and accurate wherever buyers are searching, from Google Shopping to sector-specific portals.
In today’s volatile markets, that discoverability translates into resilience. When one sales channel slows, others can fill the gap.
Case study: TYGRIS future-proofs its industrial business
TYGRIS, a family-run business in Scotland, has been supplying cleaning, lubrication, and protection solutions to industries since 1971. Like many manufacturers, TYGRIS faced the challenge of modernising its sales processes.
In 2020, the company launched a B2B ecommerce site on BigCommerce’s B2B Edition. Features like a quick order pad and purchase order workflows enabled its customers to buy more efficiently, while real-time inventory visibility proved invaluable during product shortages at the height of the pandemic.
The impact was transformative: between 2020 and 2021, TYGRIS achieved a 145% increase in conversion rate, a 99% increase in orders, and a 138% increase in revenue.
As Jed Simpson, General Manager at TYGRIS, put it:
“We chose BigCommerce because it can scale at the same level and speed as we do. The platform gives us the scalability, flexibility and openness we need to implement changes exactly when our customers need them.”
Proof over promises
For directors and senior managers in the manufacturing and processing industries, investing in digital transformation can feel daunting. Budgets are significant, change management is complex, and the wrong platform choice can be costly. That is why independent validation is so critical, and why BigCommerce’s track record stands out.
BigCommerce has consistently been rated a top performer by Paradigm B2B, the analyst-led commerce technology report. In the 2025 reports, BigCommerce was awarded 24 medals across the Mid-Market and Enterprise editions.
As the highest-rated B2B ecommerce solution for customer satisfaction on G2,
BigCommerce customers report achieving return on investment in as little as six months, less than half the industry average.
BigCommerce has been named a Leader in Worldwide B2B Digital Commerce Applications by IDC MarketScape, praised for its open SaaS model, scalability, and ability to integrate seamlessly with ERP, PIM and CRM systems.
Highlighted as a Challenger in the 2024 Gartner Magic Quadrant for Digital Commerce Report, BigCommerce was recognised for its rapid pace of innovation and unique ability to serve both B2B and B2C businesses on a single platform. Together, these endorsements form a powerful message. Ecommerce with BigCommerce is not an experiment, but a proven growth strategy that delivers measurable impact for manufacturers, processors and distributors worldwide.
Building resilience in manufacturing
The future of manufacturing is global, digital, and increasingly customer-centric. Trends shaping the next decade include:
• AI-powered personalisation: enabling predictive reordering and customised recommendations for buyers
• Sustainability demands: with customers requiring greater transparency across the supply chain
• Omnichannel fulfilment: integrating
ecommerce with physical operations to meet buyer demands for speed and flexibility
By building digital-first infrastructure today, manufacturers can respond to these shifts with agility. Ecommerce is not just about selling, but future-proofing a business for whatever comes next.
What’s next?
For the processing and manufacturing sectors, the message is clear: ecommerce is no longer a nice-to-have, but a business imperative. From efficiency gains to customer retention and global growth, digital commerce provides the foundation for resilience in uncertain times.
Manufacturers who act now will not only meet the expectations of today’s buyers but also position themselves for the opportunities of tomorrow.
BigCommerce is proud to support manufacturers and processors on this journey, helping them not only get online, but grow online.
Maintenance teams face relentless demands to cut downtime, manage costs and raise efficiency. A Computerised Maintenance Management System (CMMS) that can scale and adapt is no longer just an operational necessity, it’s a strategic partner. The right CMMS helps organisations climb the maintenance maturity curve with confidence.
Maintenance maturity is not a destination but an ongoing progression, from reactive “firefighting” fixes, through structured preventive maintenance, and ultimately towards predictive, datadriven decision-making. A scalable CMMS grows with a business, delivering the right tools at the right time.
Early on, asset registers, planned preventive schedules, and work tracking provide the essential foundations. As maturity advances, however, an CMMS must support compliance automation, real-time monitoring and advanced analytics to unlock efficiency gains.
ShireSystem CMMS is designed with this growth in mind. It empowers organisations at every stage, whether aiming for 40–59% planned work under Essential maintenance, striving for 60–79% under Advanced Preventive, or targeting predictive strategies exceeding 90% planned activity.
Roadmap for long-term success
ShireSystem’s tiered plan model (Essentials
> Professional > Advanced > Expert) ensures users can move steadily up the maturity scale without the need to overhaul systems or retrain teams from scratch. It’s a structured approach that future-proofs a CMMS investment.
The benefits are measurable. Organisations progressing their maintenance practices typically achieve:
• Energy savings of 5–10%
• Reductions of 20–40% in inventory costs
• Labour efficiency gains of 10–20%
• Fewer emergency breakdowns
• Lower overtime expenditure
These aren’t theoretical figures, they’re based on real results from real users.
Compliance, collaboration and control
As businesses evolve, compliance shifts from being a challenge to being an expectation. A forwardlooking CMMS supports this by embedding audit readiness into daily workflows. ShireSystem’s Document Manager integrates directly with assets and jobs, providing version control, metadata search, and bulk upload/download functions.
The result? Less paper, faster collaboration, reduced risk, and stronger alignment with sustainability goals. For teams working across multiple sites or handling complex assets, features like the 3D viewer bring clarity and strengthen teamwork.
A CMMS should do more than handle today’s workload; it should evolve with an organisation’s long-term maintenance ambitions. ShireSystem is built on this principle, offering a flexible, scalable path towards higher levels of maturity. For maintenance managers who want to stay ahead, now is the time to see how ShireSystem can shape the future of maintenance strategy.
Meet ShireSystem on the road
This November, ShireSystem will be hitting
the road around the UK with a series of in-person events dedicated to helping maintenance leaders understand and accelerate their maturity journey. These roadshows will provide practical insights into maintenance strategies and demonstrate how ShireSystem’s latest functionality can make a difference.
Keep an eye out for the dates on our website and social media channels, it’s the perfect opportunity to connect with the ShireSystem team, ask questions, and see how a future-ready CMMS can transform operations.
elecosoft.com/shiresystem
Drive Return on Investment at Every Stage of Your Maintenance Maturity Journey with our Scalable, AI-Ready CMMS
Smarter maintenance powered by your asset data.
From reactive to predictive, we’re with you.
Simple to set up. Easy to use. Built for results.
Where are You on Your Maintenance Maturity Journey?
If you’re ready to take the next step, why not book a personalised demo to see how ShireSystem can support your maintenance transformation
Machine Vision’s Role in Digitalisation
Stephan Pottel, Manufacturing Strategy Director EMEA, Zebra Technologies, explains why there can be no digitalisation without frontline data.
Manufacturing has long relied on statistical process control (SPC) to optimise production processes, though these methods have inherent limitations. Sampling-based data collection paints an incomplete and potentially inaccurate picture of actual production processes. It can also impede real-time feedback controls used to optimise operations in real time. Today’s digitalisation requires much more comprehensive data, which is largely being generated on the frontline.
Machine vision, in contrast, captures real-world data about physical products and processes, including detailed geometric measurements made with subpixel accuracy, surface quality assessments, positional data, colour and contrast variations, and other characteristics.
Vision systems also reveal temporal trends across production runs. By pairing vision data with sophisticated analytics, manufacturers have already experienced demonstrable benefits, revealing correlations between process parameters and quality outcomes that statistical methods might otherwise miss.
What’s the point of digitalisation
Digitalisation and digital transformation are really a means to an end – to make work and everyday life better for organisations, their employees, and those they serve. And an increasing focus is being given to the frontline – where data is generated, captured digitised and analysed on the spot, supporting automated and intelligent work around visual inspection.
Digitalisation is the process of using digital technologies like 3D sensors, smart cameras and machine vision software with
deep learning models to transform existing business models, processes, services, and products.
It involves leveraging technologies such as machine vision to improve efficiency, productivity, and customer experiences. It is not about converting analog information into digital formats (digitisation) but focuses on the broader implications of integrating digital technologies into various aspects of a manufacturing business.
Unknotting the data question
Data is the lifeblood of digitalisation, but data management has a number of hurdles. There can be multiple data owners, formats and storage sites that need to be standardised. And as the volume of data grows, so do the storage and computation demands.
Operations and IT leaders also face trying to integrate data from multiple sources using legacy manufacturing execution systems and enterprise resource planning systems. And a lack of variety reflecting real-life use cases and environments will lead to insufficient data when it comes to deep learning AI model training and testing. These challenges can be exasperated if cloud-based solutions are not considered.
To address these issues, new deep learning AI models, data capture, cloud platform and analysis solutions are being developed which open new avenues for data sources that are currently underused.
In manufacturing, things like defects and anomalies in materials, components and finished items, packaging quality, labelling, barcodes and characters, quality of returned items are the wonky data that’s highly valuable thanks to today’s machine vision solutions.
The opportunity manufacturers can’t afford to miss
The evolution toward smart automated manufacturing environments makes machine vision and vision analytics increasingly essential for competitive success. Integrated with closed-loop process controls, for example, machine vision analytics can help a production line automatically adjust process parameters based on real-time quality measurements.
As manufacturing becomes more connected, automated, and data driven, the ability to leverage comprehensive process data for optimisation becomes a key differentiator. By adopting digital technologies like machine vision, 3D and AI, businesses can overcome longstanding challenges, reduce inefficiencies, and build a foundation for future success.
Manufacturers have the tools, insights, and opportunities to create new ways of working that drive growth and innovation. Those who invest in better digitalisation of their workflows today will lead the industry tomorrow, ensuring a brighter, more scalable future for all.
Learn more about turning manufacturing data into machine vision analytics here: bit.ly/4mTy7YD
Stephan Pottel, Manufacturing Strategy Director EMEA, Zebra Technologies
Real-Time Location Systems.
The next step in warehouse efficiency.
• Track the position of forklift trucks and other transport vehicles.
• RFID tags on individual products or pallets.
• Forklift reads all the tags on a pallet.
• Combine height data from forks with location data and RFID data.
• Software automatically tracks every movement of products.
• Integration with ERP and WMS systems.
• Real time reporting.
• Fulfills Auditing requirements.
• Operator guidance.
The Potential of Energy Consumption Data
Energy consumption is of increasing concern to manufacturers trying to reign in their operating costs. In this article from Inspired PLC, the UK’s leading energy and sustainability consultants, discover how businesses can leverage energy consumption data in strategic decision-making.
Manufacturers face an uphill battle when it comes to energy; daily operations require power – at a premium. To begin to tackle this challenge, you need to know exactly how, when and where your business uses electricity and gas.
Creating a comprehensive picture of your consumption allows you to pinpoint unusual usage, efficiency opportunities and wastage across large portfolios and energy intensive sites, and demonstrate the impacts of your efforts to stakeholders.
Energy data is not just numbers; it is a strategic asset. Powerful energy decisionmaking is founded in accurate, current and accessible data. Let’s examine some of the ways you can begin to create this foundation.
Are you visualising your energy data?
Your metering solution plays a crucial role in building a comprehensive image of your consumption. Many larger businesses will have access to their half-hourly data as standard – retrieving this allows you to understand your usage patterns on a daily, weekly and seasonal basis.
When you have current metering data coming in, you must then turn these into insights that can inform your operational or strategic energy decisions.
An online platform can help you visualise your energy use so you can start comparing sites and pinpointing any unusual consumption, inefficiencies and wastage across large portfolios and energy intensive sites.
What about submetering?
Submetering involves installing additional meters to measure energy usage
downstream of the main utility meter, in near real time.
Submetering allows businesses to monitor individual processes or assets, giving you a more granular insight and better control over high-consuming areas of buildings or specific equipment.
And that’s not all. Submetering can be used to help quantify return on investment for implemented energy reduction initiatives. It may also be required for businesses claiming Climate Change Levy (CCL) discounts.
How about profile alerts?
Staying on top of any unusual consumption becomes more challenging the larger and more complex your estate is. For example, a programming error can mean a piece of equipment switches on unnecessarily when nobody is in the building.
A profile alert service constantly analyses your half-hourly meter feeds and sets thresholds that track your site consumption. When these thresholds are breached, alerts are sent to your site managers with details of how much waste has occurred, its
likely causes, and what impact this excess will have if left unresolved.
Have you looked behind your meter?
With circuit-level monitoring you can do just that. As the name suggests, circuit-level monitoring goes behind the billed meter and allows you to monitor specific circuits within your sites.
The wireless, non-invasive sensors offer up-to-minute readings and far more detailed visibility of your consumption and carbon emissions than what is available from a billed meter.
This cost-effective solution is quick to install with minimal disruption, empowering you to understand your consumption in even greater detail, and enabling your onsite colleagues to pinpoint any inefficient equipment or operations.
No matter where you are in optimising your energy consumption, there is always an opportunity to revise how to further reduce your energy usage and create cost savings. Inspired can make this happen.
inspiredplc.co.uk
UK’s Manufacturing SMEs Save Big on ERP
Traditional ERP systems can take years to implement and are often prohibitively expensive to small and medium sized companies. Here, UK manufacturers share their experiences of using a resource planning system designed for the SME market.
MRPeasy is a manufacturing resource planning system designed specifically for small and mediumsized companies. This focus on SME manufacturing already sets it apart from others on the market that started as accounting or inventory tools or as offshoots of huge ERPs like SAP. But the real difference lies in its cost and user-friendliness.
Clients laud the system’s accessibility
Andy Nancollis, CTO of Motion Impossible, a camera dolly systems manufacturer from Bristol, highlights the price of the software: “The cost was a big factor—most ERP systems are big and quite expensive, so MRPeasy stood out from the start. While very affordable, it still manages to offer everything we need, with plenty of room for us to grow into the software. This seems to be unique to MRPeasy.”
Colin Hart, Managing Director at power electronics manufacturing company Poweronics from St. Neots, got the software up and running in a single day. “The implementation was very straightforward— setting up MRPeasy only took me about three hours,” he says, “that’s 1500 SKU lines, all the bills of materials, existing sales orders, purchase orders, manufacturing orders, everything!”
“I set MRPeasy up myself, and it was that easy,” says Ralph Jones, Director at Britannia 2000 Holdings, a surveillance technology manufacturer from Windsor. “The online help has been really quick to respond to any issues.”
The right functionality for every industry
MRPeasy offers the necessary functionality
for a diverse range of industries. This includes everything from precision engineering, electronics, and industrial machinery to food, chemicals, and packaging.
For Intake Engineering, a precision engineering company from Whitstable, MRPeasy has been transformative. “I can manage the business even on my phone at home,” says Lee Brien, Director. “I can look at the jobs, see where the material is, see what’s coming in, see progress on the shop floor, and so forth. It’s fantastic!”
Hovat, a food packaging manufacturer from Aylesford, used to track inventory with a software developed in the 1970s. Recently, they moved to MRPeasy and streamlined everything from order management to costing. “It’s a lot easier to trace anything now – just a simple report, accessible right within the app. We’re saving hours and hours compared to the old way of tracing any item. In addition, it’s a lot easier for us to see where cost increases are eroding a customer’s margin with MRPeasy,” says
Colin Hart, Financial Director. Ryan Brogan, Co-Founder of Lisburnbased industrial cleaning systems manufacturer Arcus Cleaning Systems, says: “We can track every stage of a project, see our profit per project, identify delays, and adjust processes as needed.”
Survey shows huge improvements after implementing
MRPeasy’s latest customer survey translates this praise into numbers. Users reported that after implementing the software, they saw average improvements of:
• 67% in inventory tracking accuracy
• 54% in operational efficiency
• 46% in cost control
• 39% in on-time deliveries
These numbers and statements from clients echo a common theme: MRPeasy delivers a high level of functionality at a fraction of the cost of traditional ERP systems, making it the ideal choice for SME manufacturers. mrpeasy.co.uk
3D Printing a Smarter Supply Chain
In an era where digital transformation is no longer a choice but a necessity, manufacturers are constantly seeking innovative strategies to streamline operations and enhance resilience. One of the most impactful, yet perhaps least understood, of these strategies is digital warehousing. We spoke with Paul Moloney, Managing Director at Midlands 3D, a leading 3D Print Service provider, to find out more.
The traditional manufacturing supply chain is built on a foundation of physical inventory, with shelves filled with parts and components. It’s a system that’s proven but is also costly and inflexible. Digital warehousing offers a radical departure from this. Physical stock is replaced with virtual inventory – digital blueprints of parts and components that are then 3D printed on-demand.
The benefits of this shift are profound and directly address many of the traditional inefficiencies. A primary advantage is the significant reduction in inventory. By eliminating the need to stockpile large quantities of parts just to hit a MOQ or EOQ, manufacturers can free up a substantial amount of capital and valuable floor space.
The mindset shift from “just-in-case” to “just-in-time” is a commercial game-changer.
Beyond cost savings, the digital warehousing strategy dramatically improves operational agility and speed. In a traditional system, a broken part could mean days or even weeks of downtime waiting for a replacement to be shipped from a distant warehouse. With a digital inventory, the part can be produced locally and on-demand, minimising delays and ensuring business continuity. This localised production also has a significant positive impact on the environment. The need for long-distance transportation is reduced, which in turn lowers both shipping costs and carbon emissions. Furthermore, as Moloney notes, 3D printing “minimises material waste by using only the necessary amount of raw material.”
The strategic implications of this shift extend to an organisation’s ability to innovate
and respond to market demands. Digital inventory provides unparalleled flexibility. A design can be updated and a new version of a part can be produced almost instantaneously. Options and accessories can expand to cover many more opportunities. This allows manufacturers to be more responsive to customer feedback and market trends. It also enables them to offer enhanced after-sales services, such as direct-to-consumer shipping of replacement parts.
Digital Warehousing though isn’t just limited to final products. The digital warehouse can also hold files for the tools required to produce parts using other processes such as jigs, moulds and formers. These items, which would otherwise take up valuable warehouse space, can be
discarded and simply printed only if they are needed in future.
For any manufacturer considering this journey, Moloney advises starting with a careful evaluation of existing parts. “Identifying which parts are 3D printable is the first stage of the process,” he says. Not every component is a good candidate, but by focusing on slow-moving or obsolete parts and production tools, companies can launch a pilot program to prove the concept and demonstrate its value.
The transition to a digital warehouse is more than just a technological upgrade; it is a fundamental shift in business strategy that promises to make manufacturing supply chains more resilient, cost-effective, and sustainable for the future.
midlands3d.com
The
Smartest Warehouse is an Empty One.
Reduce inventory costs and the risk of surplus stock by printing on-demand from stored digital blueprints.
Cut costs, not corners. Get in touch with Midlands 3D today to arrange a no obligation consultation.
AI-Powered Robots and UK Manufacturing
Confronted with labour shortages, rising operational costs, and increasing demand, manufacturers are urgently seeking solutions to sustain productivity and competitiveness. Here, ABB Robotics UK explains how Artificial intelligence (AI) integrated into industrial robotics is emerging as a key enabler with the potential to transform the UK’s manufacturing future.
For those who are passionate about raising the UK’s manufacturing productivity, it has long been a source of frustration that the UK continues to trail behind many of our international competitors when it comes to the use of robots. With just 119 robots per 10,000 workers1 in 2023, described by the International Federation of Robotics (IFR) as ‘very low for a Western European country’2, we lag far behind nations such as Germany and South Korea as well as countries that we wouldn’t normally have seen as close competitors.
Encouragingly, as automation becomes more accessible and advances such as simplified programming and AI lower the barriers to adoption, there are signs that this gap could be set to narrow. The UK industrial robotics market, valued at around USD 475 million in 2024, is projected to grow at a compound annual growth rate (CAGR) of nearly 13% over the next decade3. Much of this growth will be driven by the evolution of AI-powered robotic systems, which can function more autonomously, adapt to dynamic environments, and collaborate directly with human workers.
The best of both worlds
The last decade has seen massive strides forward in both robots and the software used to program and operate them. Major milestones have included the development of compact robots, the evolution of cobots and mobile robots, and the arrival of software tools that enable even the least experienced users to quickly master programming robots.
Another area of development has been robot vision. Coupled with the power of AI intelligence, vision is opening new possibilities for robots to interpret and respond to their surroundings, enabling them to make decisions and adapt their performance accordingly.
Rather than replacing jobs, these robots offer new ways to augment the abilities of human workers by taking over monotonous, dangerous or ergonomically challenging tasks and allowing people to focus on oversight, problem-solving, and higher-value activities.
One of the most visible changes enabled by AI is the expansion of autonomous mobile robots (AMRs). Unlike previous generations of technology such as Automated Guided Vehicles (AGVs), AMRs do not rely on magnetic strips or fixed paths. Instead, they use technologies such as simultaneous localisation and mapping (SLAM) to navigate
warehouses, identify obstacles, and optimize travel routes without manual intervention.
Companies developing such technologies have made substantial progress in simplifying the deployment of robotics, including through the development of software to remove the complexity of programming and operation. ABB’s AMR Studio software, for example, enables users to configure an AMR fleet using intuitive drag-and-drop tools, reducing reliance on dedicated programming expertise. These advances are effectively equipping robots with “eyes, hands, brains and mobility”, mirroring and supplementing the versatility of human workers whilst offering enhanced levels of endurance, precision and adaptability.
Another innovation under development will allow robots to understand spoken or visual instructions using generative AI, eliminating the need for coding altogether. These
changes are significantly lowering the time and cost associated with robot deployment, while making automation viable even for companies with limited technical resources.
The impact of AI-enhanced robotics has the potential to transform a broad range of UK manufacturing sectors. In the automotive and electronics industries, for example, these systems can be used to assemble complex components at increased levels of speed and precision. Robots equipped with AI-based vision systems can identify parts, assess their positioning, and make any necessary adjustments in real time, resulting in higher quality and fewer defects.
In the food, beverage, and consumer goods sector, AI-powered automation offers the potential to improve efficiency and ensure consistency by enabling robots to adapt on the fly. This could include sorting and packaging products at high speed, adapting to variations in shape or format, and inspecting items for defects, all without interrupting the flow of production.
In logistics and warehousing, robots are already increasingly managing material flows without requiring human direction. Picking robots combining vision and AI can identify package types, decide the optimal storage location, and even adjust operations in response to seasonal demand changes. These capabilities are especially valuable as online retail and just-in-time delivery models continue to reshape the supply chain landscape.
Getting workers ready for AI
Unlocking the full potential of AI-powered robotics in the UK will require continued investment in people and processes. One of the most significant challenges is workforce readiness. While robots can take on repetitive tasks, their successful integration depends on people who understand how to manage, maintain, and improve automated systems. Recognising this, industry and government bodies are expanding apprenticeship programs and training schemes focused on automation and robotics engineering.
The long-awaited UK Industrial Strategy contains various provisions for providing the necessary training to equip both current and future workers with the skills needed to work with AI and AI-enabled technologies, including robots. Measures include £275m to fund technical training and apprenticeships, including courses
in AI and digital manufacturing, as well as the establishment of AI Skills Hubs to train workers in areas including advanced manufacturing and digital services.
Unlocking new possibilities for UK manufacturing
AI-powered robotics is set to evolve. Ongoing improvements in areas including cloud computing, digital twins, and industrial connectivity will see robots becoming not just more autonomous, but also increasingly integrated into a larger digital infrastructure. In the future, data collected by robots will help inform production planning, predictive maintenance, and even product design, opening new possibilities for manufacturers
to link their factory operations more closely to market demand.
By reducing complexity, improving adaptability, and enabling smarter collaboration between people and machines, AI-powered robots offer a practical path forward for UK manufacturers facing mounting pressure. Whether in large plants or small workshops, the age of intelligent automation has the potential to reshape the foundation of industrial productivity in the UK.
abb.com/global/en/areas/robotics
1Source: Automate UK, referencing International Federation of Robotics World Robotics 2024 Report
2Source: Tony Blair Institute for Global Change – A new national purpose: The UK’s opportunity to lead in next-wave robotics
3Source: imarc - UK Industrial Robotics Market Overview
20 Years of Adhesive Dispensing Expertise
As Rockingham Systems celebrate 20 years in business, MEPCA had the opportunity to speak with Callum Murray, Sales Director and co-owner, about the benefits of dispensing technology.
Rockingham Systems are a family run engineering company specialising in metering, mixing and dispensing systems for adhesives, resins and sealants, as well as automation of these processes. Callum Murray joined over 12 years ago, and has worked is way up from servicing & Installations to Sales Director and joint owner of the company.
What are the key benefits our audience can expect from utilising your engineered dispensing systems?
Primarily your audience can expect choice to fit their process requirements and budget, as we have such a large portfolio of dispensing equipment to choose from at varying cost points/levels of accuracy. Alongside our own range of FlowDose metering and dispensing systems, we are also the sole UK distributor for Nordson ICS Cold Materials (Automotive & Battery) as well as being distributors for other key industry players, such as Graco, Fisnar, Nordson EFD, and Aplicator AB, enabling us to tailor our offering to suit any technical requirements and budget.
What pointers would you give to anyone looking to specify and buy a dispensing system?
I would say ultimately to know your process and what you want to achieve, and have the Technical Datasheet (TDS) for your chosen material to hand, as every supplier will want this upfront. Then I would say the most important metrics are how you want to apply the material, in what volume and how quickly, coupled with a realistic budget to help any supplier narrow down on the One other important part I would like
to mention is that often customer choices or specifications can ultimately lead to increased cost of the system, so try not to over specify. If +/-5% repeatability is good enough for your process, stand by that, but if you are asking for +/-1% that will increase the cost. Likewise, other decisions made before you start to look for a system can increase the cost, including packaging.
How committed is Rockingham Systems to innovation and new technology development?
We are extremely committed to innovation and new technology. On average over the last few years, we are developing at least two systems a year, sometimes more; this ranges from simple dispense controllers to work with 6-axis collaborative robots like Universal Robots, developing our turnkey automation platforms and implementing progressive cavity pumping technology within our FlowDose range of continuous flow metering systems.
A particular favourite of mine is FlowDose VCM, a metering system designed to dispense from 2-part plastic cartridges but with the repeatability and accuracy of a highlevel bulk meter. This system was designed to work with thermal paste materials, which are like liquid sandpaper, but as it is direct from the cartridge, there are no wearing parts to service or replace.
Do you offer customised solutions at request, catering to specific industry requirements?
Yes, the majority of the systems we supply are customised in some way to suit the customers’ requirements, and we try to tackle this by making our system controllers as modular as possible. This means that all regular options are already in the software,
such as low-level sensor or pressure sensors. We use IO link to tackle this, as it is a modular, expandable platform.
On top of this, we also offer automation for any of our dispensing systems. So beyond the process equipment itself, we can tailor a complete solution to the customers’ requirements be that a semi-automated solution just for the dispensing process, or a fully automated turnkey system.
rockinghamsystems.co.uk
Expert solutions for the metering, mixing and dispensing of all types of adhesives, resins and sealants as well as many other fluids and pastes.
Optimising Hydraulic Performance
Titan Enterprises shares key insights to help engineers and operators navigate the challenges of precision flow metering to ensure accurate measurements and safe process operations.
Metering liquids under pressure may seem straightforward at first glance – install a flowmeter in the product line, connect it to an instrument, control the measurement with on-board software, wire in a valve and pump, and switch the flow system on. However, real-world applications reveal a host of complexities that must be addressed to achieve precise and repeatable results.
Where hydraulic systems are concerned, flowmeters play a critical role in maintaining system integrity and effectiveness. Sustaining consistent process conditions, however, can be challenging. Hydraulic systems rely on the precise movement of fluid to transmit power; any deviation from the required flow rate can lead to performance issues, excessive wear, or system failure.
Ideally, hydraulic system designs should aim to minimise as many variables as possible within a reasonable cost. Once this foundation is established, equipment such as flow meters, pumps and valves can be selected to effectively compensate for any parameter variations.
Flowmeters are designed to measure the rate and/or volume of fluid flowing through a hydraulic system via a variety of outputs, from a simple mechanical display to full data logging, providing real-time data on the rate of fluid movement, monitoring system health, detecting leaks or blockages, and optimising performance. Accurate flow measurement is also crucial for maintaining consistent pressure and ensuring that actuators and other components receive the correct volume of fluid.
Hydraulic fluids are typically viscous oils, petroleum or synthetic-based, utilised for their stability at operating temperature and lubricating properties.
Critical considerations for hydraulic fluid systems
1. System repeatability:
Hydraulic stability is essential. Air pockets in the line can lead to dynamic flow situations, causing volumetric errors in delivery. Ensuring a hydraulically locked system eliminates such variability and enhances repeatability.
2. Stable process conditions:
Changes in pressure, temperature, or flow rate can push flowmeters into unpredictable operational zones, affecting calibration and accuracy. Maintaining consistent conditions is vital for reliable performance.
3. Pulsating flow management:
Pulsation from certain pumps can disrupt flow rates, especially in aggressive chemical applications. Pressure regulators and pulsation dampers should be incorporated into flow systems to achieve a smooth and constant flow.
4. Strategic placement of flowmeters:
Positioning the flowmeter just before the dispense valve minimises fluid inertia and improves measurement accuracy.
5. Understanding the impact of viscosity on flowmeter accuracy:
Selection of any flow measurement device should always consider the fluid viscosity as turbine meters typically loose accuracy and performance as the fluid viscosity increases; whereas the performance, accuracy and range of positive displacement flowmeters increases with viscosity.
6. Valve selection and calibration:
Fast-acting solenoids are ideal for smaller pipelines, while larger setups benefit from solutions like multi-stage shut-off systems or “automatic overrun compensation” programming to fine-tune results.
7. Optimising electronic flowmeters:
High-performance meters (such as Titan’s ultrasonic Atrato® flowmeter) can predict stop signals in advance, ensuring consistent delivery even at high speeds.
Enhancing process efficiency
Hydraulic systems, particularly in the aerospace industry, are operating at increasingly higher pressures, making the selection of an appropriate flowmeter becomes even more critical. These flowmeters must not only provide accurate measurements but also be capable of withstanding pressures beyond the system’s maximum operating levels, incorporating a suitable safety factor to ensure long-term reliability and safety.
By accounting for these factors during system design and commissioning and investing in the appropriate flow measurement technology that suits the application requirements, engineers can eliminate common pitfalls in liquid metering and ensure the liquid flow system performs with precision and consistency. For more information, visit Titan’s website. flowmeters.co.uk
A Dive into Digital Pressure Transmitters
ESI Technology, Wrexham-based designer and manufacturing of pressure measurement solutions, introduces its versatile range of innovative digital pressure transmitters: GD4200-USB & RS-485.
In an era where digital precision and connectivity drive industrial performance, ESI Technology stands out with its cutting-edge digital pressure transmitters. Among the most versatile of its line-up are the GD4200-USB and the RS-485 compatible transmitters — both offering exceptional performance and seamless integration into modern systems.
GD4200-USB: plug, measure, analyse
At the heart of ESI’s digital innovation, the GD4200-USB provides a direct USB connection to a PC, enabling pressure data acquisition without the need for additional interface boards. Powered via USB, this transmitter pairs with the free ESI-USB® software for effortless setup — users can be operational in under ten minutes, thanks to auto-detection and configuration features.
Built with Silicon-on-Sapphire (SoS) sensor technology, the GD4200-USB offers sturdy durability, superb corrosion resistance, virtually no hysteresis, and longterm stability across broad temperature ranges. Users benefit from high-resolution readings (greater than 1 in 10,000), selectable sample rates up to 1,000 Hz, and a wide accuracy of ±0.15 % BFSL (NonLinearity, Hysteresis & Repeatability).
Capable of handling pressure ranges from vacuum up to 5,000 bar, the GD4200-USB suits a wide array of environments — from lab testing and leak detection to aerospace and general industrial use. Further enhancing its utility, the ESI-USB software supports monitoring of up to 16 pressure inputs simultaneously, offers automatic temperature compensation, custom certificate generation, and integration with C#, VB, LabView, and Excel VBA via API DLL.
In scenarios where remote monitoring is essential — perhaps in harsh industrial plantrooms or long-distance installations — ESI’s RS-485 pressure transmitters deliver. The GS4400 series, for example, utilise RS485 serial communications with proprietary protocols, supporting up to 32 transmitters on a single bus.
These RS-485 models uphold the same SoS sensor advantages — resilience, corrosion resistance, long-term stability, and wide temperature performance — making them ideal for hydraulic systems, refrigeration, compressors, HVAC, aerospace and medical applications.
Crucially, RS-485’s capability to transmit data over 500 to 1,000 metres ensures that logging PCs remain in safe, controlled environments — monitoring without exposure.
Why choose ESI’s digital transmitters?
• Robust sensor technology: the Siliconon-Sapphire design ensures both precision and durability under stress.
• Flexible connectivity: choose USB
for direct PC interfacing or RS-485 for distributed, long-run monitoring.
• Wide pressure range: With coverage from vacuum to 5,000 bar, the range fits diverse industrial needs.
• Powerful, user-friendly software: the ESI-USB software excels in usability — multi-input logging, auto-updates, custom certificates, VB/C#/LabView/API support.
• Adaptable fit: whether for R&D labs or rugged industrial settings, ESI’s digital transmitters deliver accuracy, reliability and ease.
esi-tec.com
Sights Set on Advanced Engineering 2025
With Advanced Engineering 2025 fast approaching, Hamamatsu Photonics is preparing to welcome attendees to its stand. Here are reasons to visit the company this year, including a preview of its technology.
Hamamatsu Photonics’ advanced technology plays a vital role in modern manufacturing processes, transforming industries by enabling faster, more precise and highly efficient production. Photonics involves generating, manipulating and detecting light and its properties; its integration into manufacturing has driven significant advancements.
Defect detection
High-resolution cameras and advanced imaging techniques allow manufacturers to detect defects, measure dimensions, and ensure product quality during various stages of production. These systems can identify imperfections that are invisible to the human eye, improving reliability. X-ray imaging also plays a critical role in non-destructive testing (NDT) and quality control, enabling inspection of internal structures without damaging components.
For example, in food processing, highspeed imaging devices such as InGaAs and CMOS cameras can be placed strategically on a conveyor belt to optimise the food sorting inspection process. InGaAs cameras use infrared technology to reveal subsurface defects invisible to the naked eye, while CMOS cameras detect visible imperfections. All defects detected will help filter out produce that should not reach the store.
Optical sensors and LiDAR
Optical sensors fill our modern vehicles, enhancing safety and comfort through features such as interactive displays and modular lighting. They also play a critical role in advancing LiDAR (Light Detection and Ranging) technology. LiDAR offers a multitude of applications for its precise measurements, detection, and monitoring
ranging from autonomous driving to automated quality control.
In manufacturing, LiDAR is revolutionising automation. By utilising laser light to measure distances, map surroundings, and detect objects, LiDAR systems are extensively used in robotics, automated guided vehicles (AGVs), and intelligent manufacturing systems for real-time feedback and control. This integration enhances workflow optimisation and productivity.
The rise of laser technology
The Era of communication
Laser technology has brought significant advancements to material processing. Laser-based systems are extensively used for cutting, welding, marking, and surface treatment of various materials. Lasers provide high-energy, focused beams that can accurately and precisely process materials, resulting in enhanced productivity, improved product quality and minimal material wastage.
Laser cutting machines deliver contactless cutting of metals, plastics, and textiles. Laser welding provides an efficient, and noncontact method for joining materials, while laser marking offers permanent and highresolution product labelling and branding. Photonics-driven 3D printing uses lasers to cure or melt materials layer by layer, enabling rapid prototyping, cost-effective smallbatch production, and complex geometries unattainable with traditional methods—ideal for aerospace, automotive, and healthcare applications.
Finally, efficient communication and data transfer is also crucial to the manufacturing environments. Fibre-optic communication systems are widely adopted for high-speed, long-distance data transmission between machines, control systems, and remote monitoring stations. Composed of glass or plastic strands, fibre-optic cables transmit light signals carrying large amounts of data thanks to integrated transmitters and receivers. Transmitter and receiver photo ICs, for example, support a wide variety of transmission speeds over a long distance at high speed, minimising latency and electromagnetic interference. Additionally, developments in quantum optical communication can provide ultra-secure, encrypted connections using low-noise, high-efficiency single-photon emitters and detectors.
Visit Hamamatsu Photonics at Stand J124 to explore how their extensive portfolio of components, modules, and systems provides innovative, high-performance solutions to the manufacturing industry. hamamatsu.com
(+44) 1707
Advanced Engineering
Visit Hamamatsu Photonics at Stand J124 to explore how our extensive portfolio of components, modules, and systems provides innovative, highperformance solutions to the manufacturing industry.
Find out more about our solutions
Light sources
• LEDs (UV – IR)
• Excimer Sources
• Quantum Cascade Lasers (QCLs)
• Deuterium and Xenon Lamps
• Extreme Ultraviolet (EUV) Light Sources
• Laser-Driven Light Sources (LDLS)
• Supercontinuum White Light Lasers
Optical sensors
• Mini-Spectrometers
• Photodiodes and Avalanche Photodiodes (APDs)
• Multi Pixel Photon Counters (MPPCs or SiPMs)
• Infrared Detectors
• X-Ray Flat Panel Sensors
• Photomultiplier Tubes (PMTs)
• VIS/NIR/X-ray Cameras
29th- 30th October 2025
Birmingham
Copper vs Aluminium Windings
In choke and transformer manufacturing, the choice between copper and aluminium windings significantly impacts cost, performance and manufacturability. In this article, electronics manufacturer REO UK examines the distinct advantages and disadvantages separating these materials.
Each material offers distinct advantages and tradeoffs that must be carefully weighed based on the intended application.
Copper is the industry standard for conductivity and remains the most efficient material for minimising electrical losses. Its superior performance enables compact choke and transformer designs with lower heat generation, enhanced mechanical stability and more predictable thermal behaviour, making it particularly suitable for applications that demand high power density, consistent thermal management, or where physical space is constrained.
Aluminium, however, has its advantages. Weighing about one-third as much as copper, it is well-suited to applications where reduced weight is a priority, this makes it especially attractive in mobile or transport systems, or in installations where lifting or structural loads are a concern. To match copper’s electrical performance, aluminium windings require a greater cross-sectional area—approximately 1.6 times larger— resulting in increased winding volume and often larger overall component dimensions.
From a manufacturing standpoint, copper is readily available in a wide range of wire diameters and is compatible with most standard winding equipment. Its mechanical robustness also makes it easier to handle during production. Aluminium, by contrast, is available in fewer standard sizes and can be more prone to damage during winding and termination.
Corrosion is another consideration. Copper is relatively inert and highly resistant to oxidation in most environments. Aluminium, on the other hand, forms a nonconductive oxide layer almost immediately
upon contact with air. This makes it essential to treat or protect connection point to ensure long-term reliability and performance.
In terms of material cost, aluminium holds a clear advantage. As of mid-2025, copper is priced around $11,000 per tonne, while aluminium is approximately $2,580 per tonne. Even after adjusting for the greater volume needed to achieve comparable conductivity, the effective cost of aluminium is about $4,130 per tonne, resulting in a material cost saving of approximately 63%. Should market conditions push aluminium closer to its projected low of $2,000 per tonne, savings could exceed 80%, offering significant cost advantages in high-volume or cost-sensitive applications.
To overcome some of aluminium’s limitations—such as oxidation, mechanical softness, and lower thermal resilience— specialised alloys like Aircunal have been developed. These alloys offer improved conductivity, structural integrity, and oxidation resistance, making them more suitable for demanding electrical applications. However, their use requires trained personnel, specific storage conditions, and potentially retooled production processes.
One area where copper remains dominant is in high-frequency applications. At elevated frequencies, alternating current tends to travel along the outer surface of conductors—a phenomenon known as the skin effect. Because aluminium has higher
resistivity, it allows slightly deeper current penetration compared to copper. While this may appear beneficial in theory, aluminium’s lower overall conductivity and its unsuitability for litz wire configurations make it a poor choice in practice. Additionally, the oxide layer formed on aluminium’s surface can further impede current flow in high-frequency conditions. Copper’s superior conductivity, compatibility with litz wire, and long-term contact reliability ensure its continued preference in these scenarios.
Both materials have valid roles to play in choke manufacturing. Copper is ideal where compactness, performance, and reliability are paramount. Aluminium, particularly when enhanced through alloys like Aircunal, is an increasingly viable choice for lowfrequency, cost-driven, or weight-sensitive designs. The decision ultimately depends on specific technical requirements, budgetary constraints, and manufacturing capabilities.
Working with a supplier that can support both copper and aluminium solutions allows for flexibility and optimisation without bias toward one material over the other.
reo.co.uk
Handheld Temperature Sensors and Probes
Combining accuracy with ergonomic design, handheld measurement solutions are convenient and versatile. But not all handheld sensors are alike in quality or function, as Labfacility explains here.
Labfacility prides itself on being a leading provider of high-quality temperature measurement solutions. Among the company’s extensive range of products, its handheld temperature sensors stand out as a testament to Labfacility’s commitment to reliability and customerfocused design. These versatile sensors are designed to meet the diverse needs of professionals across industries, offering precision and ease of use in equal measure.
Meeting the needs of professionals across industries
Labfacility understand that accurate temperature measurement is critical in industries ranging from food safety and pharmaceuticals to HVAC maintenance and industrial processes. That’s why its handheld temperature sensors are engineered for portability, real-time results and long-term dependability. Whether used for ensuring compliance with HACCP regulations or maintaining industrial equipment, these products are tailored to help users achieve the highest standards of performance.
What makes these handheld probes exceptional?
The round-handle-style handheld temperature probes combine functionality with ergonomic design, ensuring they meet the practical needs of customers. Here are some of the features that set them apart: Comfortable, ergonomic design: the round handle of Labfacility’s probes is designed for ease of use, offering a secure and comfortable grip even in challenging environments. Whether you’re working in a cold storage facility or a busy industrial site, the design minimises operator fatigue and
ensures consistent performance.
Wide range of sensor options: one size doesn’t fit all. That’s why these handheld probes are available with a variety of sensor types, including thermocouples (types K, T, J) and RTDs (Pt100). This flexibility allows customers to select the ideal probe for their specific applications.
High accuracy and responsiveness: precision is at the heart of these products. The best handheld probes are designed to provide fast and accurate readings, enabling professionals to make critical adjustments with confidence. Whether monitoring food temperatures during production or calibrating sensitive equipment, these sensors deliver dependable results.
Built to Last: durability is key when it comes to professional-grade equipment. That’s why Labfacility’s probes are constructed with robust, high-quality materials that resist wear, corrosion, and extreme temperatures. Users can rely on these sensors to perform reliably, even in the most demanding environments. Customisation: every application is unique, and Labfacility are proud to offer customisation services for its handheld probes. From bespoke lead lengths to specific handle designs and sensor configurations, it works closely with its customers to deliver solutions tailored to their requirements.
A commitment to quality and innovation
Labfacility have built a reputation on delivering temperature measurement solutions that meet the highest standards of quality and reliability. Its range of handheld temperature probes reflect this dedication to supporting professionals with products that simplify their work and enhance efficiency.
Ease of purchase
Through partnerships with Digikey and Farnell, Labfacility’s customers now have multiple convenient options to access highquality temperature measurement products. Both Digikey and Farnell stock an extensive selection of Labfacility’s products, including thermocouples, RTDs, and Connectors, ensuring they can quickly find the specific product needed for an application. With a reliable service and global distribution networks, they can trust that their order will arrive promptly and with the highest level of care.
labfacility.com
Access the Future: Register for EDS 2025!
FREE registration is now open for the Engineering Design Show (EDS), 8–9 October 2025, Coventry Building Society Arena. Following last year’s success, EDS 2025 is set to welcome over 4,800 mechanical, electronic, and embedded design professionals, making it the biggest edition yet.
As the UK’s leading event for the engineering design community, EDS continues to attract innovators, decisionmakers, and technical specialists eager to explore the latest technology shaping product development. Across two days, visitors can meet 220+ exhibitors spanning product design, 3D printing, embedded systems, PCB manufacturing, motors, sensors, robotics, and more.
Industry-Leading Suppliers
More than 220 suppliers will gather under one roof, representing electronics, embedded systems, robotics, motors, sensors, materials, and product design. Headline sponsors Würth Elektronik and Solsta highlight the breadth of expertise available. Würth Elektronik showcases its expanding portfolio, including IQD Frequency products, alongside full design-in support and delivery. Solsta (formerly Solid State Supplies) focuses on semiconductors, embedded modules, communications, power management, LED lighting, relays, switches and optoelectronics.
Visitors can also explore products from Maxon Motor, Telonic Instruments, Yokogawa Test & Measurement, Peli Products, Hitek Electronic Materials, TTI, Robafoam, Smallfry Industrial Design, and The Peak Group, reflecting the diversity of industries represented at EDS.
Conference programme
The 2025 conference is designed for design engineers across sectors from aerospace and automotive to electronics and consumer products. Attendees will gain insights into transformative technologies like Artificial
Intelligence and Quantum Computing, while sessions provide strategies for sustainable product development, patent protection and career-focused guidance.
Key highlights include:
• Don’t Forget Me! – A human-centred approach to simulation and digital twins (Claire Palmer, Loughborough University)
• Panel discussions on supply chain resilience, security, and defence careers (Angela Lamont)
• Pass EMC the First Time – Design it right from the start (Min Zhang, Telonic)
Work in defence
New in 2025, the Work in Defence feature, in partnership with The Engineer, provides a platform for connection with leading defence organisations. Attendees can explore skills pathways, career routes and opportunities at the Work in Defence Roundtable hosted by Jon Excell.
What’s on?
EDS 2025 brings engineering creativity to life. Visitors can:
• See the Dynium Robot, an autonomous agricultural vehicle with OxDrive high-torque electric hubs, performing precision tasks in orchards and polytunnels.
• Explore KUKA Robotics’ nextgeneration Autonomous Mobile Robots (AMRs), featuring flexible fleet management software, no-code programming, and solutions for automation integration.
• Take part in the Rollapaluza cycling challenge, racing on Condor track bikes with real-time scoring on a giant display.
• Discover student innovation at the NTU Student Showcase, including Joshua Dennis returning with his business Dennistries, unveiling the NextGen humanoid robot line, including NextGen LEO.
These live experiences capture the spirit of EDS, letting attendees meet innovators, test technologies, and witness breakthroughs in robotics, human-focused design and advanced materials.
Networking and community
Hands-on workshops provide practical skills for design engineers, while the Chill & Charge Zone offers space to recharge and network. The EDS Party in Dhillons Lounge caps off day one with cocktails, live music and raffle prizes.
See you there!
Don’t miss the UK’s biggest engineering design show. Explore innovations, meet industry experts, and shape the future of engineering – all with free registration. Sign up today! engineeringdesignshow.co.uk
Discover Innovation at Advanced Engineering
The UK’s largest annual gathering of engineering and manufacturing professionals is back and bigger than ever, and it’s not long until the doors open. Advanced Engineering 2025 returns to the NEC, Birmingham on 29 & 30 October, offering a powerful platform for the entire industrial ecosystem.
With over 400 exhibitors, including 130 new and 200+ expert speakers, this year’s show is poised to reflect the fast-changing needs of UK industry — from Net Zero targets and digital transformation to skills development and supply chain resilience.
A pivotal moment for UK manufacturing
This year’s event lands just months after the UK Government announced1 a 10-year industrial strategy that promises to reduce electricity costs by up to 25 per cent for more than 7,000 manufacturing firms, while unlocking billions in investment for R&D, AI and energy infrastructure.
The renewed long-term focus on industry is energising the sector — and Advanced Engineering is where that momentum will be felt most.
“Every year, we see the latest innovations on display and the energy from exhibitors and attendees proves just how important this event is,” said Simon Farnfield, Event Director at Easyfairs UK & Global. “The 2025 edition is set to deliver even more value for visitors and exhibitors alike.”
Innovation takes centre stage - especially for SMEs
The SME Village is one of several show zones that will champion early-stage innovation, allowing agile manufacturers to exhibit side-by-side with sector leaders. Nearby, the Electronics Zone and the AM2 Forum (Additive Manufacturing and Advanced Materials) offer even more opportunities to explore cutting-edge technology.
A growing focus on composites
This year also sees the return — and significant expansion — of the Composites Pavilion, now in its fourth year and fully booked well ahead of the event. Delivered in partnership with Composites UK, the pavilion offers easy-access pods for companies to exhibit with confidence.
“Composites UK’s partnership with Advanced Engineering is essential as it highlights the transformative potential of composite materials, fosters innovation and creates valuable business connections that contribute to the growth and development of the composite manufacturing sector,” said Dr Sue Halliwell, operations manager at Composites UK.
Live demonstrations from PRF Composite Materials will also headline the pavilion, showcasing high-performance prepreg systems and recycled carbon solutions. Meanwhile, the Composites Forum will present two full days of expert-led content.
Smart factory transformation, front and centre
Advanced Engineering also sees the return of Atlas Copco as sponsor of the Automotive & Aerospace Networking Lounge. A standout feature from last year’s show, the lounge will again host demonstrations and discussions around Smart Factory transformation, covering automation, vision inspection, data-driven analysis and sustainable production.
“By harnessing digitalisation and advanced tooling, manufacturers are reshaping their production environments,” said Jessica Porter, Marketing & Comms Manager at Atlas Copco Tools & Industrial
Assembly Solutions. “It’s all about making sustainability, productivity and profitability work together — not in isolation.”
Addressing the skills gap
As part of its ongoing commitment to supporting the UK’s industrial future, the show will also continue its #MINDTHEskillsGAP initiative. The campaign brings together industry, education and government to tackle the talent shortage in engineering and manufacturing. Visitors can expect a series of sessions, workshops and networking opportunities that explore how to attract, retain and upskill the next generation.
What’s more, Advanced Engineering is once again co-located with Lab Innovations, with all attendees receiving a single badge granting access to both shows. With over 9,000 professionals expected, the event continues to serve as a key meeting point for industry leaders, R&D teams and decisionmakers.
Advanced Engineering UK 2025 is shaping up to be a milestone event. Visitor registration is now open and early registrants will receive exclusive updates on exhibitors, speakers and feature areas.
This is the second time I’ve been here; it’s the principle of keeping your finger on the pulse. You can keep up to date with novel innovations.
Josh Surga
Engineer
Association partners
5 free CPD accredited forums
1000s of innovative solutions
400+ suppliers
10,000+ engineering professionals Scan here to register
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The Heart of British Manufacturing Returns
Southern Manufacturing & Electronics will return to Farnborough International Exhibition & Conference Centre 3-5 February 2026, bringing with it the full breadth of innovation, expertise and dialogue that has established the show as the UK’s leading industrial showcase.
Each year, Southern Manufacturing & Electronics attracts thousands of design engineers, procurement specialists and business leaders eager to explore the latest advances across electronics, automation, precision engineering and manufacturing technology. The 2026 edition promises to be no exception, offering visitors a unique opportunity to see first-hand how the sector is adapting to the profound challenges and opportunities facing the industry today. It’s also set to be the biggest edition in the show’s history, with over 90% of the floorplan already sold.
At its core, the strength of Southern Manufacturing & Electronics lies in its ability to provide a panoramic view of the industrial landscape. Few exhibitions manage to combine such diverse disciplines under one roof. From electronics assembly and automation systems to CNC machining, composites, and high-performance materials, the exhibition floor offers an immediate snapshot of the technologies driving competitiveness. For many, the event is not simply about products on stands, but about understanding how digitalisation, sustainability and supply chain resilience are shaping the future of manufacturing.
Digital transformation is likely to be a recurring theme across both the exhibition and the accompanying seminar programme. The tone has shifted markedly from discussion of future potential to showcasing real-world case studies, where digital tools are already delivering measurable improvements. For manufacturers still weighing the business case for investment, the event offers timely and actionable insights.
Sustainability will also feature prominently. As the UK accelerates its transition towards
net zero, manufacturers face pressure not only to decarbonise their operations but also to demonstrate sustainability across entire supply chains. Exhibitors and speakers alike will address issues ranging from energy-efficient automation and low-carbon materials to the circular economy and waste reduction strategies. The exhibition provides a valuable forum for exploring how to embed these principles without compromising competitiveness.
Exhibitors such as Silclear, Jenks & Cattell Engineering, Cross Manufacturing and PRV Engineering illustrate the diversity of expertise on display. Their offerings, spanning silicone extrusion, precision pressings, high-performance sealing and advanced fabrication, demonstrate how UK engineering continues to adapt and thrive in an increasingly demanding global market. Their participation also highlights another enduring strength of the show: its ability to bring SMEs and larger manufacturers together in ways that spark collaboration, strengthen supply chains and accelerate innovation.
Regional engagement further enriches
the picture. Initiatives such as InvestFife’s Trade Development Programme, which has used the event to spotlight local businesses on a national stage, underline the role that manufacturing plays in regional economies as well as in the broader industrial fabric of the UK. These success stories offer a useful perspective on how national challenges around skills, productivity and investment are being addressed through local action.
Southern Manufacturing & Electronics 2026 represents more than a trade show. It is a live case study of where UK manufacturing stands today, and where it is headed. The show floor offers the chance to engage directly with new technologies, while the seminar programme provides a forum for reflection and debate on the issues shaping industry’s long-term future. Whether the priority is sourcing new suppliers, discovering sustainable technologies, or simply gaining insight into the direction of travel for UK manufacturing, Farnborough will be an essential destination this February. southern-manufacturing-electronics. com/en/
The Heart of British Manufacturing & Electronics
10000+ attendees 28 years as the South’s leading industry show
550+ exhibitors
Kickstart 2026 at Southern Manufacturing & Electronics - the UK’s leading industrial event. Join 550+ suppliers, from global giants to agile SMEs, in one dynamic marketplace. Connect, innovate and drive your projects forward at the South’s essential meeting point for manufacturing and electronics.
I’ve found it incredibly useful - great for sparking new ideas and making valuable contacts. It’s exciting to discover a wide range of technologies and products I hadn’t come across before. It’s an excellent way to stay up to date with the latest industry trends. The event is massive, with so much to see. I’d definitely recommend attending, and I’m really looking forward to the seminars!
Peter Bates, Design Engineer, Rolls-Royce
3D Print Manufacturing
Midlands 3D Printing
T: 01785 594389
E: sales@midlands3d.com
W: www.midlands3d.com
Anti Vibration Products, Mounts & Bushes
Fibet Rubber Bonding (UK) Ltd
T: 01282 878200
E: sales@fibet.co.uk
W: www.fibet.co.uk
Connectors & Cabling Solutions
CEMBRE Ltd
T: 01675 470 440
E: sales@cembre.co.uk
W: www.cembre.com/en
Design-In Power Supply Solutions
Ideal Power
T: 01733 309865
E: salessupport@idealpower.co.uk
W: www.idealpower.co.uk
Drives, Motors & Gears
Flow Meters
Nord
T: 01235 534404
E: GB-sales@nord.com
W: www.nord.com
Industrial Fans
Axair Fans UK Limited
T: 01782 349 430
E: sales@axair-fans.co.uk
W: www.axair-fans.co.uk
Machine Safety
Schmersal UK Ltd
T: 01684 571980
E: uksupport@schmersal.com
W: www.schmersal.co.uk
Marking Solutions
T-Mark
T: 0330 153 8320
E: sales@t-mark.co.uk
W: www.t-mark.co.uk
Pressure Measurement Specialists
ESI Technology Ltd
T: +44 (0)1978262255
E: sales@esi-tec.com
W: www.esi-tec.com
Robotics & Automation
KUKA Robotics UK Ltd
T: 0121 505 9970
E: sales.uk@kuka.com
W: www.kuka.com
Sensors
Titan Enterprises Ltd
T: +44 (0)1935 812790
E: sales@flowmeters.co.uk
W: www.flowmeters.co.uk
High Shear Mixing Equipment
Silverson Machines Ltd
T: +44 (0)1494 786331
E: sales@silverson.co.uk
W: www.silverson.co.uk
Industrial Communications
Brainboxes
T: + 44 (0) 151 220 2500
E: sales@brainboxes.com
W: www.brainboxes.com
Intoware
T: 0115 977 8969
E: hello@intoware.com
W: www.intoware.com
IFM Electronic
T: 020 8213-0000
E: enquiry.gb@ifm.com
W: www.ifm.com
PLUS Automation Ltd
T: 0121 58 222 58
E: Sales@PLUSAutomation.co.uk
W: www.PLUSAutomation.co.uk
Storage Solutions
BITO Storage Systems Ltd.
T: 02476 388 852
E: Info.uk@bito.com
W: www.bito.com
Test & Inspection
AMETEK Land (Land Instruments International)
T: +44 1246 417691
E: land.enquiry@ametek.com
W: www.ametek-land.com
Kraus & Naimer
Enclosed switches & functional handles
Customisable,high-quality,robust materials
Variants include: Pushbuttons With or without auxiliaries
Emergency stop function
GRIFFSERIE | HANDLE SERIES FH10
GEHÄUSESERIE | ENCLOSURE SERIES SE02
Membrane keypad LED lighting
Scan to website for product data
Funktions-Maschinengriff mit ringbeleuchteten Drucktastern und verschiebbaren Griffschenkeln | Functional machine handle with ring illuminated push buttons and adjustable handle shanks
Funktionsgehäuse mit Leistengriff für Profilsysteme, rückseitige Befestigung |
rear attachment
Werkstoff und Oberfläche:
Griffsteg aus Edelstahlrohr ø 30 x 1,5 mm, Werkstoff-Nr. 1.4301, feingeschliffen. Drucktastergehäuse aus Aluminium AlMgSi 0,5; schwarz eloxiert. Griffschenkel aus Polyamid PA 6, schwarz mit Feinstruktur.
Profilaluminium AlMgSi 0,5; gestrahlt und naturfarben eloxiert. Endkappen aus Aluminium AlMgSi 0,5; naturfarben eloxiert.
Funktionselemente ab Werk:
• 1 Drucktaster mit LED (Wechsler)
Funktionselemente ab Werk:
• 2 Drucktaster mit LED (1 Wechsler, 1 Schließer)
• Not-Halt (2 Öffner)
• 2 Drucktaster bis 1 A mit roter bzw. grüner Ringbeleuchtung
Anschluss:
• 2 Drucktaster bis 1 A mit roter bzw. grüner Ringbeleuchtung, Not-Halt (2 Öffner)
Verschiebbare Griffschenkel
Anschluss:
Stecker 8- oder 12-polig
Schutzart:
Stecker 8- oder 12-polig
Schutzart:
IP 65 (bei aufgeschraubter Kupplung)
Lieferumfang:
Zubehör Seite 56 Accessories page 56
Zubehör Seite 56 Accessories page 56
Auf Anfrage:
IP 65 (bei aufgeschraubter Kupplung)
Auf Anfrage:
Für die Befestigung sind 2 selbstsichernde Nutensteine M6 enthalten.
Kundenspezifische Variante, Beschriftung, Kupplung mit 10 m Leitung als Zubehör lieferbar.
Andere Grifflängen, Laserbeschriftung unterhalb der Drucktaster sowie beleuchtetem Not-Halt, andere LED Farben. Kupplung mit 10 m Leitung als Zubehör lieferbar.
Beschriftung auf Anfrage | Labeling on request:
Durchgehende Nut in der Anschraubfläche für variablen Anschraubabstand. Continuous groove for a variable bolting distance.
Kraus & Naimer
ctrlX OS is Cyber Resilience Act-ready, Bosch Rexroth’s secure-by-design, IEC 62443-certified platform delivers built-in protection and easy to manage sercurity updates, helping automation systems meet CRA requirements with ease.
