Future of Manufacturing IE - Q4 2023

Future of Manufacturing Q4 2023 | A promotional supplement distributed on behalf of Mediaplanet, which takes sole responsibility for its content

“The twin digital and green transition will bring challenges and opportunties that require an agile response.”

Rachel Shelly, Head of Life Sciences & Food and Talent, Transformation & Innovation, IDA Ireland

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With a special Life Sciences feature on Page 05

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“Generative AI holds significant promise for developing greater value for participants.”

Micheal Cassidy, CTO, Irish Manufactuirng Research

Page 06 Image provided by Digital Manufacturing Ireland

Our clients realise that cutting-edge technology is important — but successful adoption of that tech is crucial. ~Digital Manufacturing Ireland on page 03

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Rachel Shelly Head of Life Sciences & Food and Talent, Transformation & Innovation, IDA Ireland

Responding to digital and green transition opportunities and challenges

Ireland’s continued resilience and robustness as an investment location is due to the remarkable fortitude and dynamism of our existing foreign direct investment (FDI) base, partnership across the entire ecosystem and with the Government.

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DA Ireland partners with 1,800 multinational companies that are diverse and spread across sectors at the forefront of the modern global economy — from biopharmaceuticals, medical technologies, engineering, technology and financial services.

abatement of energy-intensive processing. Digitally enabled manufacturing and sustainability practices are increasingly intertwined, as we see with the arrival of continuous manufacturing to life sciences sites.

Digital growth in Irish manufacturing Strategy for Ireland to win new A strong ecosystem is key to investment success. IDA recently supported Volatility and headwinds facing the €21 million expansion of NIBRT the global economy mean we to respond to the research and have to work even harder to win training needs of the cell and gene new investments. IDA’s strategy therapy community. In March, (2021–2024) is centred around five Minister Coveney launched Digital pillars: growth, transformation, Manufacturing Ireland (DMI) regions, sustainability and impact. in Limerick. Industry-led and The transformation pillar focuses complementing existing resources, on increasing the competitiveness, DMI provides a collaborative agility and physical and digital resilience of environment for Manufacturing Irish operations the acceleration through RD&I, of technologies to remains a significant digitalisation, ‘digitise’ Ireland’s contributor to the talent manufacturing development and base and supply Irish economy. In sustainability. This chain partners.

2022, it accounted for Critically, DMI strategy directly aligns with the provides training 39% of GDP and €208 Government’s in emergent billion in exports.

White Paper on platforms to upskill Enterprise 2022– the workforce in 2030. line with future production skills needs.

Value of manufacturing in Ireland Ireland does not take our success Manufacturing remains a significant to date in attracting and retaining contributor to the Irish economy. investment for granted. The twin In 2022, it accounted for 39% of digital and green transition will GDP and €208 billion in exports. As bring challenges and opportunities manufacturers look to develop and that require an agile response. As drive innovative future pipelines, companies navigate an increasingly national Industry 5.0 capabilities complex path to international are becoming the benchmark for success, Ireland stands ready as an attracting high-value, flagship open, stable and reliable partner. investments.

Organisations are pivoting towards agile, flexible, digitally enabled manufacturing platforms that also offer opportunities for significant

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How manufacturers can set new standards in efficiency and sustainability A food and drink multinational has been optimising its operations through a programme of digital transformation while implementing eye-catching sustainability initiatives.

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o get ahead in today’s competitive manufacturing landscape, companies must be prepared to set new standards for flexibility, efficiency and sustainability. That’s what multinational PepsiCo has done, says Brian Colgan, Site Lead at the Ireland manufacturing operation at Little Island, Cork, which produces a range of beverages including Pepsi, PepsiMax, 7up and Gatorade.

Advantages of a digital transformation system Recently, the Little Island plant transformed its operations by successfully piloting a digital factory system. “Digital transformation was vital for us because the complexity of our business is growing fast,” says Colgan. “Our volumes are climbing, new product ranges are expanding and regulatory challenges are increasing. Using devices rather than paper-based systems gives us access to meaningful real-time data from the production process, making our operations more flexible and helping us achieve the fastest possible response times.”

As a result, the plant is better able to quickly absorb supply bottlenecks and shortages — and react speedily to fluctuations in demand. “Digital transformation has also enhanced our quality control,” says Colgan. “Plus, it’s supporting volume and planning efficiency and inventory management.” He advises businesses starting a digital transformation journey to have a strong change management focus, including training and competency development for all its people.

became fossil fuel-free. “We’re proud to be one of the first fossil fuel-free PepsiCo sites across the globe,” says Vincent Goggin, Site Lead, Carrigaline. “The key is Hydrotreated Vegetable Oil (HVO), which we’re using to power on-site boilers and heating, ventilation and air conditioning systems.”

The Carrigaline facility is investing in heat-pump technology and onsite renewable generation, too; and it’s working on energy partnerships with other local industries to pool resources against their climate goals. It also broke records when it opened Ireland’s largest rooftop solar photovoltaics (PV) installation in May. “We make a lot of investments in our site,” says Goggin. “But solar PV generated so much excitement among our employees and garnered a huge amount of interest in the local community. It also caught the attention of applicants who tell us that they want to work in a place that is making a real effort to be more sustainable. So, apart from being good for the planet and people, sustainability is a competitive advantage.”

Introducing record-breaking sustainability improvements PepsiCo is working to have net zero emissions by 2040, and Ireland is at the forefront of this initiative.

In November, its manufacturing operations at Carrigaline, Cork,

Find out more pepsico.com

Brian Colgan Site Lead, Little Island, PepsiCo Ireland

Vincent Goggin Site Lead, Carrigaline, PepsiCo Ireland WRITTEN BY Tony Greenway

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If we bring new tech in, but our people don’t want it, like it or use it, then we might as well not have it.

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Why data-driven manufacturers need tech, people and a strategy for success Successful data-driven manufacturers won’t just need to employ cutting-edge technology.

They will also require human-centric skills and workforces that are adaptive to change.

W Domhnall Carroll CEO, Digital Manufacturing Ireland WRITTEN BY Tony Greenway

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hat will the factories of the future look like? Increasingly, they will become both data-driven and human-centric. From an outside perspective, that might sound like a contradiction of terms, agrees Domhnall Carroll, CEO, Digital Manufacturing Ireland — a national industry-led organisation focused on driving digital technology adoption across Irish-based manufacturing.

However, he argues that to become data-driven — which is key to success — an organisation will require three things: strategy, technology and people.

Supportive role of effective technology Automation has always tended to remove the influence of people from manufacturing. Think about robots on assembly lines, for instance.

What’s coming next will be a gamechanger, predicts Carroll. “New technology — such as AI — will transform how people work in manufacturing,” he says. “It will equip them with all the data they need to become more informed and enable them to use their human creativity. Tech’s role will be to support humans by giving them the tools they need to do the best job possible.”

Latest technology will help humans make big decisions Technology will still be employed to take care of drudge work — which

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is as it should be, says Carroll. “That will continue and leave humans to concentrate on answering questions, such as: ‘How can manufacturing processes be improved?’ ‘What makes a good product?’ and ‘What builds a reliable and resilient supply chain?’ It’s a paradigm shift that will invite increasing numbers of people into manufacturing. So, the industry is set to become more human, not less human.”

While the latest technology will have a sizeable impact on operations and be the leverage for scale, it won’t be running the show. “In the short-term, I expect to see AI making lots of small decisions, but the big ones will still be made by humans,” says Carroll. “Manufacturing sites won’t become ‘AI sites.’ They will be managed, staffed and run by people who are very good at making lots of complex manufacturing judgments — and AI will help them in that task.”

Building human-centric skills in manufacturing organisations This is why it’s so important to build human-centric skills in manufacturing organisations and create workforces that are adaptive to change. “We find that the organisations we work with understand the need to optimise their resiliency and flexibility, especially when they think about what’s happened over the last five years,” says Carroll. “They also know that more change is coming.”

The best way to deal with that

change is to have a workforce that can roll with the punches and deal with anything that comes their way. “That’s the skillset and the culture that companies are asking us to support them with the most,” reveals Carroll. “In fact, the thing that really excites them is when we start talking about the ‘people’ aspect of manufacturing. Our clients realise that cutting-edge technology is important — but successful adoption of that tech is crucial. They tell us: ‘If we bring new tech in, but our people don’t want it, like it or use it, then we might as well not have it.’ For us, it’s about presenting them with the best solution, not simply a technology one.”

Working collaboratively to solve manufacturing challenges The challenges that manufacturing faces can’t be solved alone, which is why DMI has established various collaboration groups for industry players to get together to share knowledge. “To address problems around technology, people and becoming a data-driven organisation, it’s vital that companies work together to inform the discussion and develop solutions,” says Carroll.

“There’s a saying: ‘If you want to go fast, go alone. If you want to go far, go together.’ Well, in the Irish manufacturing industry, we’re going far — and together.”

Find out more at dmireland.org

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Accuracy in Industry 4.0: A prerequisite for manufacturing’s leap to 5.0 In the ever-evolving landscape of manufacturing, the transition to Industry 4.0 stands as a crucial milestone.

What a digital twin can tell you about your warehouse capital plans

Digital and AI skills identified as key for next healthtech evolution

Future capacity plans need to be underpinned by a clear picture of current sourcing and inventory practices and a picture of how existing warehouse, receiving, marshalling and shipping areas are used.

Ireland has the potential to establish itself as a global hub for the next AI-powered evolution in healthtech, but that potential may go unrealised if we fail to develop the skills required to compete.

everaging supply chain volume and dimensional data can present a clear picture of actual inventory practices and how existing warehouse and material flow capacity is used. Frequently, this will highlight differences from stated inventory processes, and capacity plans will need to reflect a range of options to support future demand.

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Processing good quality data The manufacturing sector finds itself grappling with a deluge of data — a veritable ocean of information generated by connected devices, machines and systems. While the potential of this data is immense, the pressing question arises: What good is data if it’s bad data? The efficacy of Industry 4.0 hinges on the reliability and standardisation of the information flowing through the digital veins of smart factories.

The need to bring every stakeholder along on this journey is paramount to every manufacturing company and its ability to compete globally. Before venturing into Industry 5.0, it is imperative to iron out wrinkles in current technological implementations and data usage, creating a foundation for seamless progression.

Align forecasts with physical requirements Bill of material (BOM) data linked with inventory policies provides insights into future storage needs. These can include ambient, cold, frozen, hazardous and flammable materials — internally and externally. These can be linked to dynamic change as long-range forecasts update and can be updated with supplier or materialspecific inventory strategies.

Flow requirements can also be mapped within a digital twin using current operational timings linked to volume growth.

It is important to understand the variability between normal and peak operational requirements.

ith eyes on Industry 5.0 already, a challenge looms — the imperative to get it right within 4.0 before embarking on this new venture.

At the heart of this pivotal juncture lies the critical issue of data: its volume, quality and, most importantly, standardisation.

Merging the physical and digital realms The future envisions a manufacturing ecosystem where the Internet of Things (IoT) and a network of sensors provide real-time insights into facilities; an intuitive digital twin serves as the nexus between the physical and digital realms. This promises heightened efficiency, waste reduction and error elimination.

However, this is contingent on the standardisation and governance of data that is increasing by the nanosecond. Standardisation becomes the linchpin, ensuring that data speaks a common language across diverse systems.

Simulate supply chain scenarios With a baseline model in place that reflects current operating parameters, the digital twin can support collaborative, data-driven discussions between manufacturing, planning and supply chain teams on the impact of material strategies, VMI operations and insource vs. 3PL. It can also produce a range of capital alternatives for the site.

The digital model goes beyond simple pallet and storage capacities and includes flow capacity — space, labour and equipment — identifying holistic needs for the site and supporting the evaluation of capital and operational alternatives to resolve them.

Standardised data enables resilience This standardisation is something we strive for in the geospatial sector: a single source of truth from which understanding can be gathered.

The informed use of geospatial data enables the integration of smart machinery and smart factories — propelled by standardised data — promising to enhance efficiency and productivity across the entire value chain.

It’s crucial the roadmap to Industry 5.0 is paved with the meticulous standardisation of data, ensuring that our manufacturing future is not only technologically advanced but also resilient and adaptive.

Keeping the model up to date Once built, the data-driven capacity model and digital twin can be maintained to reflect operational choices and perform a digital ‘what-if’ in support of future supply chain initiatives. Ideally, the original development of the capacity model should include considerations for data maintenance — BOM and forecast updates, new products and operational improvements — with clear owners and expectations on update frequency.

JP Kelly Associate Director, Murphy Geospatial Lorcan Sheehan, CEO, PerformanSC

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rtificial intelligence (AI) has emerged as a transformative force across industries, and the life sciences sector is no exception.

Ireland’s world-class healthtech ecosystem already boasts 700+ businesses, which employ 89,000 directly across both the world’s top biopharma, medtech and digital health companies.

Campaign for digital health solutions Connected Health Skillnet was established under the ‘Where Digital Health Thrives’ campaign — a joint initiative of BioPharmaChem Ireland, Irish Medtech Association and Technology Ireland. It has already identified 200 companies delivering digital health solutions in Ireland — with market segments including digital therapeutics, precision medicine, data analytics, cybersecurity, remote monitoring, mobile health and more. The Connected Health Skillnet was established under the Where Digital Health Thrives campaign to develop high-end niche talent at the healthtech intersection.

Companies engaging in digital health Our Network recently launched the Future Skills Needs Analysis for Digital Health report, which showed that 87% of companies surveyed are planning to increase their digital health activity over the next four years, and they intend to invest.

Another 87% confirmed that their Irish operation will play a key role in their planned digital health activities, and 82% of companies have partnered with other businesses to develop digital health solutions — and this trend is also reflected globally.

AI was identified by 52% of companies as a top current and future skills need. According to Galen Growth global research, there were 247 partnerships in digital health announced last year — up from 59 in 2018, and 90% of these partnerships are using AI. Putting capabilities in place for innovation We’re upskilling talent to navigate the growing complexities across the value chain, with a strong emphasis on regulation and R&D. In the EU alone, having the skills to navigate the evolving regulatory landscape — including the AI Act, Cyber Resilience Act and European Health Data Space Regulation — will be key, as well as ensuring we continue to build innovation capability.

Jennifer McCormack Manager, Connected Health Skillnet, a joint initiative of BioPharmaChem Ireland, Irish Medtech Association and Technology Ireland

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Traditional and generative AI: an insight into the new normal for pharma firms Artificial intelligence (AI) is transforming the way medicines are made. Expert knowledge and good data analysis remain vital to the life sciences equation, however.

W David Staunton Head of Transformation, Life Sciences Manufacturing, Cognizant

Jacqueline Hora Digital and Data Analytics Consultant, Life Sciences Manufacturing, Cognizant

hen David Staunton, Head of Transformation, Life Sciences Manufacturing at Cognizant, is asked if AI will transform the way that the life sciences industry will operate in the future, his answer is: “It’s already doing it.” For example, AI — which excels at the super-fast processing of vast amounts of data — is already having a big impact on the way that medicines are discovered, launched and made.

Revolutionary impact of AI in pharma manufacturing “Pharma companies have been able to synthesise around 1,000 molecules a year for drug discovery purposes,” says Staunton. “With AI, they can analyse 50 billion molecules a year. For context: if you count to 1,000, it takes about 15 minutes. If you counted non-stop to 50 billion, it would take you approximately 1,500 years. So, AI is completely game-changing for pharma companies.”

Every area of the pharma industry is feeling AI’s effects — including early discovery, clinical development, manufacturing, supply chain, commercialisation and even the digitisation of factories. Ultimately, that’s great news for patients who continue to benefit from new and more personalised treatments.

“AI significantly reduces drug development and launch timelines,” says Staunton. “As a result, new therapies will get to market faster.” AI is also altering the competitive landscape, with tech firms expected to increasingly enter the space traditionally populated by pharma companies.

Well-crafted data strategy can help manufacturers Hora points out that the more meaningful and contextualised the source information that an AI solution has access to, the better insights it will generate.

“Contextualising your data is critical to understanding past performance and using historical data to predict future outcomes,” she says. “Contextualising data starts when equipment and process systems are configured, and it typically involves combining details from multiple sources to build a comprehensive picture of events.

“A well-crafted data strategy will enable this seamlessly, ensuring data from your systems are easily accessible and usable. In AI solutions, the foundation for generating accurate and dependable information and insights lies in the availability of high-quality and reliable source data, instilling a high level of confidence in their accuracy and authenticity.”

AI isn’t a replacement for life sciences knowledge.

Paid for by Cognizant

Data-driven approaches to drug development Staunton is, however, keen to flag up how ‘traditional’ AI (which recognises patterns in data) and ‘generative’ AI (which generates new content based on data) are used in the life sciences sphere.

“There’s no doubt that generative AI can be super-helpful to pharma companies,” he says.

“However, the technology is not quite there yet. For example, it can’t make GMP (good manufacturing practice) decisions, and it’s not writing GMP reports without human-approved validation.”

Going forward, pharma companies will use AI to accelerate the development, manufacture and marketing of their products, says Jacqueline Hora, Digital and Data Analytics Consultant, Life Sciences Manufacturing at Cognizant. Developing a cohesive data strategy — which AI solutions consume — to generate insights is key.

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Value of quality data and expert interpretation for AI purposes Cognizant is currently working on a use case where generative AI will form part of a solution to provide advisory support to new technicians. Key to the success of this solution is the capture of previous knowledge and experience of manufacturing operators to use as a knowledge base.

“There is an impression that AI can fix things when it can’t,” Hora states. “If you put bad information into your system, you’ll get bad information out.”

AI isn’t a replacement for life sciences knowledge, says Staunton. Instead, expert data analysis is — and will remain — crucial. “You’ll have to be able to read and interpret the data AI gives you in order to understand if it’s sound or not; this will become a key people skill,” he says. “Our increasing use of AI means that data is only going to become more important in the years ahead.”

For more information on how Cognizant can help life sciences manufacturing companies on their digital transformation journey, visit: cognizant.com/ pharmamanufacturing

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Manufacturing leaders highlight industry challenges and opportunities The manufacturing sector, integral to the Irish economy, employs over 275,000 people. It contributes significantly to total employment and regional development.

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n Ireland, the manufacturing sector stands at a pivotal juncture, as detailed in Ibec’s enlightening 2023 Manufacturing report.

The report, encapsulating the views of 39 trade associations, portrays a landscape of cautious optimism; marked by challenges but also laden with opportunities.

Confidence ratings among manufacturers The year 2022 was a banner year for Irish manufacturing, with a record-breaking €208 billion in exports. This remarkable achievement highlights Ireland’s role as a crucial gateway to Europe, especially postBrexit, bolstered by a skilled workforce, strategic location and supportive government policies. However, the sector’s journey is not without obstacles.

The report reveals a nuanced picture of business confidence. While the current environment is seen more positively than last year, with the ‘very good and good’ rating rising from 53% to 70%, it still trails behind the 89% confidence level of 2021. This suggests a recovering but still cautious sentiment among manufacturers. Business leaders are more optimistic about the next six months, with confidence ratings improving from 39% to 66%.

Talent demands and rising costs Despite these promising signs, challenges like talent attraction and retention remain. With 67% of leaders concerned about this issue, the sector is countering with 72% of businesses anticipating wage increases and 32% planning workforce expansion. Housing availability, a worry for 47% of leaders, underscores the need for infrastructural development to make Ireland an attractive place for professionals.

Rising operational costs, including raw materials, transport and energy, also pose significant challenges. The sector’s response involves embracing sustainability and digitisation, with 85% engaged in sustainability initiatives and 68% in digitisation. These strategies are pivotal not just for compliance but for operational efficiency and cost savings.

Navigating challenges and opportunities The Ibec report is a call to action, urging policy refinement to meet industry needs. It underscores the need for government support in digitalisation, sustainability and R&D to enhance global competitiveness. The right mix of policies, innovation and investment can steer the sector towards a prosperous future, as it navigates the delicate balance of challenges and opportunities.

Scan the QR code for the full report and a deeper insight into this sector’s journey.

Sharon Higgins Executive Director, Ibec

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How useful is generative AI in manufacturing and supply chains?

The rapidly increasing ability of generative AI tools is creating huge interest in their potential in the data-rich environments of manufacturing and supply chains.

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hile there is a lot of aspiration for generative AI use in shopfloor and operational applications, the technology is likely going to have the earliest impact in providing productivity in customer and supply chain engagement. It can deliver streamlined and automated solutions for quotes, order preparation, inventory management and bespoke documentation, which supports customised production.

Micheal Cassidy CTO, Irish Manufacturing Research

However, there are significant challenges to making the technology useful for industry, foremost of which are risks of misinformation — many generative AI tools are prone to creating fictitious outputs. There are concerns over privacy and security and the lack of skills to deploy and effectively use the technology.

The digital skills gap is significant According to a recent KPMG survey of US manufacturers, many companies intend to develop Generative AI allows the exploitation of knowledge stores and deploy their own solutions, yet most lack The technology will support the the skills to do so. Developing cataloguing of service knowledge foundational AI knowledge and provide conversational across organisations as well as There are concerns interaction with customers. specific expertise will be critical over privacy and Within industry, tools will provide for industrial competitiveness in insights from the plethora of security and the lack Ireland. reports, PowerPoints and assorted Within global supply chains, of skills to deploy documents that constitute a vast in which Irish industry is hugely wealth of static organisational interconnected, generative AI holds and effectively use knowledge. significant promise for developing the technology.

Irish Manufacturing Research greater value for participants and (IMR) researchers have started for supporting an evolution to to deploy generative AI tools to circular economic models. interact with machine data and complex outputs Coupled with smart products and Digital Product from other data analytics tools. This will support Passports, generative AI can help in telling the more intuitive and conversational reporting at both history of a product, aiding full lifecycle support, shopfloor and management levels. remanufacturing and second-life uses. IMR, in It will, in time, significantly increase the collaboration with Irish industry, leads research actionable insights that can be developed from to develop and deploy the building blocks of this manufacturing data sources that are largely sustainable manufacturing future. underutilised in most factories. IMR research has also deployed generative AI to develop synthetic data for training other AI models in flexible automation challenges.

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Cyber resilience at the core: operational technology in smart manufacturing

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As a Gold partner, Nostra has a team of highly skilled professionals, experienced in a wide range of products, from servers and storage, converged and HCI, to data protection, networking and cloud integration. Our close working partnership and extensive data centre experience enable us to deliver end-to-end solutions.

Image provided by Dell & Nostra

Peace of mind for business leaders We aim to provide business leaders with peace of mind, knowing their manufacturing environment is secure against cyber threats. Our comprehensive approach covers everything from the protection of legacy systems to the implementation of robust cybersecurity measures for modern OT assets. By partnering with Dell Technologies, we can deliver robust infrastructure, through secure supply chains, with air-gapped data protection to ensure production lines stay online.

In the manufacturing sector, one significant challenge is the prevalence of older servers and hardware, which can become substantial cybersecurity vulnerabilities.

Senan Finucane Co-Founder and CTO, Nostra

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e ensure full protection of your manufacturing environment by focusing on often-overlooked areas in cyber resiliency. This commitment to security becomes even more crucial in light of recent research from industry leaders, which highlights the susceptibility of operational technology assets to attacks.

Cybersecurity tackling the risks of outdated infrastructure Operational technology assets, crucial in manufacturing, are now among the most targeted by cyberattacks. Assets, including engineering workstations and SCADA servers, are prime targets due to their expansive attack surface and known weaponised CVEs. We prioritise the modernisation and security of these legacy systems, ensuring they are not the weak links in our clients’ cybersecurity armour.

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Security and storage in simplifying deployment and integration We prioritise robust and scalable storage capacities that align with the operational demands of modern manufacturing, enabling quick and informed decisions across all levels.

This approach is vital for managing the data generated in operational technology (OT) environments, which are increasingly complex and susceptible to cyber threats.

Scaling manufacturing resilience with embedded cybersecurity As manufacturing capabilities expand, especially in OT environments, embedding rigorous cybersecurity measures becomes imperative. This need is underscored by the rising threat to assets like engineering workstations and PLCs. Dell’s end-to-end security portfolio allows us to provide cyber resiliency across IT and OT environments when developing our customers’ 4.0 projects.

Pioneering a secure, efficient future in manufacturing Our focus extends to PLC security, safeguarding critical infrastructure and implementing robust measures against a variety of cyber threats.

With our global presence and commitment to security, we drive the manufacturing industry towards a future where operational excellence and cybersecurity are inextricably linked.

Since our inception in 2006, we have established ourselves as Ireland’s leading IT company, with a global presence across Ireland, the UK, Bulgaria and South Africa. Our team of 250 dedicated professionals brings a wealth of experience in industrial cybersecurity and operational technology, forming the foundation of our approach to secure smart manufacturing.

Collaborating to shape the present and advance manufacturing In the ever-evolving world of manufacturing, the strategic collaboration between Dell Technologies and Nostra emerges as a powerful catalyst, propelling the industry toward heightened security, innovation and operational efficiency. This partnership is not just a transaction; it’s a testament to the shared vision of both entities in revolutionising manufacturing environments.

State-of-the-art storage solutions play a pivotal role in this narrative, seamlessly integrated into the OT landscape by Nostra. Together, we navigate the complexities of modern manufacturing, addressing challenges and fortifying systems against cybersecurity threats with a focus that goes beyond conventional business collaborations.

Find out more at nostra.ie

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The crucial role of research in manufacturing our sustainable future Representing 34% of Ireland’s economic output and employing over 20% of the workforce, Ireland’s manufacturing sector stands at the forefront of economic growth.

I Dr Siobhan Roche Director, Science for the Economy, Science Foundation Ireland

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nternationally, the manufacturing landscape is undergoing unprecedented disruption, fuelled by technological advancements such as artificial intelligence, automation/robotics, additive manufacturing (3D printing), augmented reality/virtual reality and digital transformation while the emergence of quantum computing promises further transformation across the sector in the coming years.

more optimised and sustainable manufacturing processes.

A new call for research centres — the first in seven years — was announced in September 2023 and features manufacturing and materials as one of six priority areas.

This provides an exciting opportunity to further bolster the sector through cutting-edge research and innovation.

Remaining competitive through innovation The European Commission’s ‘Industry 5.0 — A Requirement to adapt to tech Transformative Vision for Europe’ Investing in research, innovation report underscores the role of digital and skills development is crucial for technologies in fostering sustainable Achieving Ireland’s companies and other organisations economic models. While several ambitious objective of to stay at the forefront of the reports have highlighted the slow technological revolution and to adoption of digital and sustainable net-zero greenhouse drive forward the development manufacturing technologies by Irish gas emissions by of sustainable manufacturing manufacturers, the importance of processes. Collaboration with remaining competitive, through 2050 will require leading academic centres can help research and development, cannot be an unprecedented, companies on their transformation overstated. This includes the ability to journey. respond promptly to emerging trends coordinated effort. like digitisation, sustainability and Value of research centres across novel manufacturing methods. manufacturing Achieving Ireland’s ambitious objective of net-zero Science Foundation Ireland awards facilitated academicgreenhouse gas emissions by 2050 will require an industry collaborations to help cultivate an ecosystem unprecedented, coordinated effort. We are all stakeholders and talent pipeline that is ready to meet the demands in that drive. Such a future envisions a low-cost, low-risk of a challenging future. Our research centres serve as design of new products and the manufacture of highinvaluable hubs that bridge scientists and engineers from value components, integrating environmentally positive academia and industry. manufacturing practices across the entire value chain.

These centres are fostering innovation, advancing With a growing emphasis on sustainability, the demand research and translating the outcomes into practical for research, development and innovation is inevitably solutions across the manufacturing sector. They specialise surging. This presents a unique opportunity for current in areas such as materials science and processing and aspiring engineers and scientists to shape the future. technologies, advanced manufacturing techniques and the application of AI and real-time data analytics to enable

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Engineering Education 5.0: how to make manufacturing fit for the future Engineering Education 5.0 aims to produce engineers who are not only technically adept but also deeply aware of their responsibility to ensure the wellbeing of individuals, communities and the environment.

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ngineering Education 5.0 is a radical, new approach to engineering education that transcends traditional boundaries and integrates technological proficiency with a robust commitment to ethics, humanism and sustainable practices.

Louise Gorman Advance Centre Manager, ATU Sligo

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Sustainable and ethical manufacturing innovation This new model is particularly relevant to the manufacturing sector in Ireland, which is facing a rapidly evolving technological landscape. Engineers need to be equipped to navigate these complexities and ensure that growth and innovation do not compromise human rights or environmental sustainability.

It places the wellbeing of workers and the planet at the heart of its approach. It encourages engineers to develop a holistic understanding of the interconnectedness of social, environmental and technological systems. Moreover, it empowers them to contribute to a more equitable, sustainable and prosperous global society.

In addition to technical skills, Engineering Education 5.0 emphasises the importance of leadership, innovation and ethical awareness. Engineers are encouraged to be leaders and changemakers, driving positive change in the industrial sector and ensuring that it serves as a resilient provider.

Growth throughout a manufacturing career Lifelong and life-wide learning is also a key feature of Engineering Education 5.0. Professionals in manufacturing need to be able to acquire digital transformation skills throughout their careers to remain competitive.

The Advance Centre provides flexible and agile options for engineers to develop these skills through

microcredentials and programmes related to digital transformation in manufacturing.

The right tools for engineers Engineering Education 5.0 is urgently needed in a world that is facing complex challenges such as climate change and social inequality.

Below are some specific examples of the manufacturing skills gap in Ireland’s digital transformation being addressed by the Advance Centre, which will provide engineers with the skills needed to develop and implement digital solutions that improve productivity, efficiency and sustainability in the manufacturing process.

• A wide range of microcredentials including robotics, operations strategy and technical communications • Undergraduate part-time, online degree programmes in manufacturing, mechatronics, electronics and quality • Part-time postgraduate certificates and Masters in Engineering Management Promoting dynamic engineering education The Advance Centre is also working with industry partners in the manufacturing sector to develop new microcredentials and programmes that integrate digital transformation skills with traditional engineering knowledge.

These are just a few examples of how the Centre is contributing to Engineering Education 5.0 in Ireland.

As the manufacturing sector continues to evolve, this new model of engineering education will be essential to ensuring that Ireland remains a leader in this field.

Uses for digital tools in more efficient advanced manufacturing Partnerships between academia and industry are helping manufacturers across Ireland become more efficient with the use of new digital tools.

A Professor Denis Dowling Director, I-Form Advanced Manufacturing Research Centre WRITTEN BY Mark Nicholls

nalysing manufacturing process data offers significant opportunities to boost yields and optimise material and energy efficiencies.

Academia and industry are seeing the development of new digital tools and processes offering solutions to manufacturing challenges.

Advanced manufacturing expertise Playing a pivotal role is I-Form, the Science Foundation Ireland-funded Research Centre for Advanced Manufacturing. Headquartered at University College Dublin with eight partners in research and academic institutions across Ireland, their research focus is on the application of digital technologies to materials processing.

Centre Director Professor Denis Dowling, explains: “We look at manufacturing processes and try to enhance their efficiency, reliability and sustainability. We achieve this by applying a range of digital tools, such

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as machine learning and artificial intelligence.”

Digital tools in manufacturing Within the past six years, I-Form has trained over 120 PhDs and postdoctoral researchers, with new skill sets combining the use of digital tools with engineering and physical sciences to support manufacturing.

“Manufacturing has a real need for expertise in using digital tools in its operations,” he says, adding that graduates have had little difficulty securing good jobs in the sector.

Another element is enhancing Ireland’s international reputation for scientific excellence, with research attracting investment while giving indigenous companies a competitive advantage. Industry-academic links are two-way, explains Dowling.

“Helping companies develop and adopt new technologies and increase efficiency is a core element of what we are doing, as well as addressing product and process development.”

Find out more at advancecentre.ie

Sustainable economic models In one example, researchers combined the outputs from machine learning data analysis to develop a novel rules-based Recommender System, which provides operators with feedback directly onto tablet devices or mobile phones.

“The ability to identify processing anomalies at an early stage, rather than after a manufacturing process has completed, clearly enhances processing sustainability and avoids waste,” adds Dowling.

Other digital tools are being developed to accelerate the prediction of optimum processing conditions. One industry partner found that the application of I-Form predictive modelling tools led to a 90% reduction in the number of physical experiments required for fabrication of its new product range.

The Centre’s work also helps companies reduce greenhouse gas emissions and address the growing shortages of critical raw materials of high economic importance in the EU. Through its ‘Industry 5.0, a transformative vision for Europe’ document, the EU Commission has highlighted the role digital technologies will play in enabling more sustainable economic models.

Find out more at i-form.ie

Paid for by I-FORM

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Additive Manufacturing: enabling design freedom of Conformal Cooling The digital design freedom inherent in Additive Manufacturing, when applied to the production of tool steel moulds, opens up new boundaries of controlled cooling.

A

dditive Manufacturing (AM), or 3D Printing, unlocks the potential to create highly complex three-dimensional designs which are not easily possible with conventional manufacturing processes. This opens up new possibilities in design complexity and precision.

Additive Manufacturing efficiencies AM can be a tool for efficiency. It allows for complex internal channels, creating winding paths with unprecedented ease. One of the most effective ways to implement this is to use it for optimising cooling paths within tooling, integral to Injection Moulding.

This optimisation, known as Conformal Cooling, closely aligns the cooling line with the cavity, significantly improving cooling, reducing cycle times and enhancing the overall sustainability of the process. As AM is fundamentally a digital workflow, applying a simulation-led design process is straightforward and can significantly de-risk the entire operation.

Conformal Cooling is fast The demand for greater production flexibility has never been higher, and Conformal Cooling is answering this call. It has revolutionised tooling, often reducing mould cycle times by over 30%. Manufacturers can utilise cooling with precision, ensuring efficiency where it matters most.

Environmental impact and global competitiveness AM extends beyond efficiency; it’s a path to environmental responsibility. By optimising tool cooling, significant energy savings are realised, reducing the reliance

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Colin Meade Additive Manufacturing Technologist, Irish Manufacturing Research

Mark Hartnett Additive Manufacturing Senior Technologist, Irish Manufacturing Research

on chilled water systems. This not only offers substantial cost savings but also lessens the environmental footprint of injection moulding.

Internationally, AM is gaining traction, with many competitors employing this technology to stay ahead. Irish firms, known for their emphasis on quality over cost, are recognising that AM is the key to remaining competitive in a rapidly evolving market and have observed a notable trend: their competitors are consistently quoting significantly reduced cycle times.

The key to this efficiency? Additive Manufacturing, specifically its application in creating conformally cooled tooling, is the driving force behind these impressive time reductions. Employing cuttingedge industrial AM capability at its Mullingar pilot factory, Irish Manufacturing Research (IMR) has successfully delivered an end-to-end production capability in Conformal Cooling for Irish injection moulding companies.

A large consumer manufacturer attests to the effectiveness of AM, stating: “For the past decade, we’ve employed AM in every tool we’ve made; we are the best in the world at it.”

Why it’s also about quality In economies with high production costs, like Ireland, AM’s value extends beyond speed. It’s about meeting stringent quality standards and handling complex designs and materials. AM offers a solution — facilitating faster production while ensuring deeper cooling penetration into the tool. This results in deeper process control and a more balanced thermal system, leading to better quality parts and significantly reducing defects and waste.

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How close university-industry collaborations are helping to bridge manufacturing skills gaps As the war for manufacturing talent intensifies, one Irish university is working with industry partners to close the skills gaps with various enterprise-focused educational pathways.

L Professor Conor McCarthy Digital Mechatronics Engineering, University of Limerick

Ray O’Brien Bernal Institute Enterprise & Research Services, University of Limerick

WRITTEN BY Tony Greenway

ow unemployment and skill shortages fuel talent competition in Irish manufacturing. University of Limerick leverages industry relationships for collaborative initiatives to bridge the skills gap.

This encompasses Ireland’s largest and longest running cooperative programme, allowing students to apply classroom learning to real-world settings and connect with industry partners. It also offers tailored training and continuing education for upskilling with up-to-date industry requirements.

Big pharma sees UL as an important stakeholder in cultivating talent, from undergraduates and postgraduates, because of their embedded problem-solving, critical thinking and technical focus. Undergraduates complete work placements and, after graduation, host companies tend to rehire them.

At the Bernal Institute, dedicated instrument scientists provide problem-solving services to manufacturing sites nationwide. University staff detail a unique approach to skills training and collaboration, addressing talent pipeline issues and creating enterprise value.

How is the university helping to address the war for talent?

“By producing more industryready graduates who can hit the ground running. For example, we’ve launched a new Integrated BE/ME Digital Mechatronic Engineering programme that explores robotic and industrial automation and includes a placement in a relevant industry setting. We designed the course in response to industry demand; it attracted 70 students in its inaugural year. As a young university, we’re agile and can adapt quickly to what the industry is looking for.”

How important are industry-university partnerships?

“Industry partnership is key to forging manufacturing excellence. The Bernal Materials Research Institute is always poised to fuel innovation and position the university as a leader in education and research. Placing industryexperienced staff within the Institute has created a unique environment — one where people from academia and industry meet and speak each other’s language. Our analytical services are driven by world-class instrument scientists who work with every size of partner from startups to multinationals. The knowledge and experience levels they have is phenomenal.”

— Ray O’Brien, Bernal Institute, Enterprise and Research Services

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Geraldine Carroll Professional Education Manager, University of Limerick

— Geraldine Carroll, Professional Education Manager

How does the university meet career advancement needs of professional learners?

“Professional learners have unique educational needs. We cater to them with a wide variety of programmes, whether it’s our Professional Doctorate or a portfolio of Master’s programmes, many are delivered online. We have Professional Diplomas that learners can stack to build a customised, interdisciplinary Master’s degree, and we offer a range of microcredentials linked to these Professional Diplomas.

The post-grad programmes we develop with our industry partners frequently inform our undergraduate degrees and help keep them up to date.”

Industry partnership is key to forging manufacturing excellence.

— Professor Conor McCarthy, Digital Mechatronics Engineering

Paid for by Bernal Institute University of Limerick

How does the university’s approach create value for enterprise?

“The Mid-West has the biggest concentration of multinationals outside of Dublin. UL collaborates with industry players on our doorstep to help fill their talent gaps through development of learning pathways; pathways that meet the learner where they are; short, accredited modules (microcredentials) — enabling progression to a Professional Diploma or Masters. With a significant portfolio of microcredentials — short, sharp, accredited modules — we enable professional learners to top up or convert their skills for career progression.”

— Professor Ann Ledwith, Director, Human Capital Initiative

Professor Ann Ledwith Director, HCI, University of Limerick

Dr Eoin O’Connell Associate Professor, Electronic & Computer Engineering Department, University of Limerick

What makes the university’s approach to industry engagement different?

“UL has a well-developed community of practice, highly skilled in supporting industry challenges. Whenever a company approaches us with a requirement for a capability that we rarely don’t possess, we take the initiative to tap into our extensive network to assist in finding a solution. As academics, we visit our students on-site and meet their managers. This nurtures our relationship further and ensures that both parties are getting the maximum benefit from that placement.”

— Dr Eoin O’Connell, Associate Professor, Electronic and Computer Engineering Department Find out more at ul.ie/gps/ professionalflexibleprogrammes ul.ie/gps/staycurious

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New university hub driving manufacturing transformation through digitalisation

A groundbreaking initiative, the Smarter Factory Technology Gateway, is carving a path toward disruptive change in manufacturing.

T

echnological University of the Shannon (TUS) is establishing a centre of excellence for Industry 4.0/5.0, driving digital and green transformation to support innovative enterprises and shape the future of manufacturing.

Dr John Cosgrove Director of Smart Manufacturing, IDEAM Research Institute

David Downey Educational Outreach Manager, IDEAM Cluster

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Empowering industry through collaboration The Smarter Factory Technology Gateway is co-funded by the Government of Ireland and the European Union through the Southern, Eastern and Midland Regional Programme 2021–2027. Working in close collaboration with Enterprise Ireland, the Gateway will partner with all of industry in the manufacturing value chain, in research projects leading to impactful innovation.

At the core of these partnerships lies a shared belief in the power of data. The Smarter Factory’s emphasis on harnessing data, through cyberphysical systems (CPS), the Internet of Things (IoT) and edge devices, lays a foundation for the effective deployment of intelligent systems, cognitive robots, computer vision systems and artificial intelligence (AI).

The University’s Researchers bring deep expertise in manufacturing systems, control, simulation, machine learning, digital twins, algorithm development, intelligent business tools and the industrial data space. A core priority of the gateway will be the practical applications of these advanced digital technologies through demonstration in realworld industrial scenarios, where new insights from smarter data can drive improved quality, predictive maintenance, increased capacity, cost reductions, improved efficiency and more sustainable operations.

The Smarter Factory’s dedication to innovation diffusion finds a natural ally in the IDEAM Industry Cluster’s commitment to nurturing SMEs and startups. This partnership actively supports these companies on their transformative journey, providing them with not just knowledge and information but also the tools needed to adopt new technologies and innovate. The result is a thriving ecosystem where external knowledge and insights are skillfully applied, leading to the development of distinctive products and processes.

Fostering innovation in SMEs and startups The IDEAM Industry Cluster at TUS, supported by the Enterprise Ireland Regional Technology Clustering Fund, is an initiative to develop the engagement between enterprise and regionally based knowledge providers. Through this initiative, IDEAM spearheads the development of a large network of industrial SMEs and startups. It facilitates the exchange of best

practices, experiences and opportunities and promotes business-to-business collaborations for investments and international partnerships.

Supported by an Industry Steering Board and regional stakeholders, the activities and strategies for IDEAM are focused on enabling SMEs to address the opportunities arising from Industry 4.0/5.0, the digitalisation of manufacturing, AI and data analytics to support the development of agile, sustainable and resilient manufacturing operations and exploit the innovation and funding potential of National and European Research Programmes.

Support from skilled digital strategists Dedicated digital strategists support and connect companies within the network. They assess business models, metrics and challenges; identify digital maturity; address knowledge gaps; and guide value-driven business transformation.

Specialist training programmes and engineering labs are available to nurture the talent needed for industry-wide digital and green transformation.

Shaping the manufacturing future IDEAM and the Smarter Factory Technology Gateway will cooperate synergistically, impacting industries ranging from multinational corporations to the dynamic landscape of small and mediumsized enterprises (SMEs) and startups.

Together, these initiatives are not merely envisioning the future of manufacturing; they are actively shaping it. The University’s Research Institute provides the intellectual foundation and expertise while the Smarter Factory Technology Gateway brings the practical application of these innovations. The IDEAM Industry Cluster spreads this knowledge with SMEs and the wider ecosystem. This dynamic collaboration is driving progress, fortifying businesses with advanced technologies, reducing costs and enhancing performance.

The future of manufacturing is not a distant prospect; it’s a tangible reality being shaped by the transformative partnership between academia and industry at TUS.

Connect with us now at ideam.ie for support from our digital strategists who will help your company chart the way forward.

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