advanced manufacturing in liverpool city region manufacturing in the uk. lcr has adopted this...

Advanced Manufacturingin Liverpool City Region

to 2020

Liverpool City Region’s Advanced Manufacturing and assembly output includes the world-renowned Range Rover Evoque produced at Jaguar Land Rover’s Halewood Operations plant.

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Executive Summary

Introduction

Vision

Manufacturing Landscape

Short-Term Opportunities

Long-Term Competency Development

Careers in Manufacturing

Consultation Process

Competency Definitions

LiverpoolLEP.org/makingit

CONTENTS

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MAKING IT 2020_Internal Page:Layout 1 25/11/2013 11:06 Page 1

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Liverpool City Region’sresearch facilities play amajor part in developingthe Knowledge Economy


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EXECUTIVE SUMMARY

This consultation document has beencompiled with a simple question in mind– what is the future for AdvancedManufacturing in Liverpool City Region?Manufacturing in the region is performingwell; productivity has increased, even ifthe sector itself has reduced over thesame period.

Across Liverpool City Region (LCR) and the wider North West there areareas for growth in Aerospace,Automotive, Marine, Chemicals, Bio Technology, Energy, Food and Drinksectors presenting opportunities toboost innovation, increase levels ofemployment and develop a globalplatform and reputation for the industry.

LCR has modernised its manufacturingbase and has developed an industry thatis now vibrant and which can be globallycompetitive. It provides a platform forjobs and productivity growth for the UKeconomy as well as the local andregional economy.

This year, LCR has worked with anumber of partners within AdvancedManufacturing to outline areas wheregrowth can be accelerated. With ashared ambition to stay ahead of thegame we have identified short-termopportunities to be exploited, each ofwhich has been identified and endorsedby the industry. We will work on longer-term competencies which will supportour ambition to be globally competitive.Each of these competencies is relevantacross the manufacturing sector andfeeds into different elements of industryacross the region. This provides adiverse base for growth.

Resources will shape the products wemake and the processes we developand evolve. If we understand what iscoming, we can plan and invest to makethe most of the opportunity and toovercome the challenges.

The work we have conducted sits withina national framework and process. It builds on the study conducted by theTechnology Strategy Board in 2012 todevelop a landscape for the future ofAdvanced Manufacturing in the UK. LCR has adopted this structure to createa landscape which maps the CityRegion’s competency and develops aroadmap for the next 15 to 20 years.

We must focus our attention and energyon our skills, experience and ability. To be economically competitive,sustainable and innovative we must work together and collaborate efficientlyand effectively. This is our landscape forgrowth and innovation.

1National Process Scale-Up

Solutions Centre

Liverpool City Region: Sustainable Energy Solutions

North West Shale GasExploration Platform

Global market leader for smart,non-invasive monitoring

Intelligentsystems &embeddedelectronics

Smart, hybrid &multiplematerials

Energygenerationmanagementsecurity andstorage

Developing and retainingskills tosupport High Value

Manufacturing

UnderstandingDesigning andManufacturingformulatedproducts

FlexibleAdaptive andScalable

Manufacturing

Design andManufacture forLight-weightvehicles andstructures

Managingfragmentedvalue chains

Biological,BioTech andSyntheticBiology

processing

SystemsModelling andintegrateddesignsimulation

Automation,Mechanisationand HMI

Developmentand applicationof advancedcoatings

New BusinessModels

Big DataMaterialsInnovationFactory

QuantumTechnology

International exemplar forMarine Ballast Water Treatment

Centre of Excellence in Light-Weighting

Short TermOpportunities thatdrive competencydevelopment andcreate competitiveness)

Globally CompetitiveCompetencies(building blocks for the future. 10 yeardevelopment cycle)

Vision for LiverpoolCity Region

A global manufacturing hotspot with the smartest networks, talent, technology and investment.

City Region has identified opportunities that align with national strategic requirements

LCR competencies which align with Nationally desirable competencies Strengths in addition to national framework


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INTRODUCTION

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Manufacturing has the capacity tochange lives. Through biotech researchinto anti-immunity drugs, light-weightvehicles producing fewer emissions,from relying less on the world’sresources to creating a skilled andexperienced workforce, manufacturing isdriven by sustainability. It can shape ourworld and its future.

We are already home to 3000+manufacturing companies, many of themhousehold names like Jaguar LandRover, Johnson Controls, ABB, Unilever,United Biscuits and Cammell Laird.Others are smaller SME’s embracinginnovation and working flexibly to createnew and world-changing products. From pharmaceuticals to shipping, car manufacturing to energydevelopment the sector employs justunder 50,000 people. It generates £3.2 billion for the LCR economy.

Making It has focused on bringing LCR’smanufacturing community together todetermine how we can meet thechallenges and seize the opportunitiesthat are coming. In LCR we recognisethe potential of Advanced Manufacturingto create a high value return to the local,regional, national and internationaleconomy, the potential to create bothjobs and economic growth.

The Making It process has been led bythe Liverpool City Region LocalEnterprise Partnership with support fromthe Institute for Manufacturing, University

of Cambridge (IFM ECS), BIS,Technology Strategy Board (TSB) andsupporting LCR based companies. The unique approach is the most in-depth study into a specific industry of its kind in the UK. It mirrors workundertaken by the Technology StrategyBoard in the production of its nationalstrategy for Advanced Manufacturing.

The consultation process has involved a series of workshops with industryexperts. The outcomes from theseworkshops are:

• A detailed understanding of the globaland national landscape for AdvancedManufacturing and how the LCR ispositioned (Section 4)

• A shared vision for what is possiblewithin the LCR (Section 3)

• A defined set of short-termopportunities that build on our existingstrengths but will also provide thefoundations for future success (Section 5)

• A focus on competencies – thoseattributes required by the LCR forsustained competitive advantage, and aligned with national priorities(Section 6)


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Detailed accompanying documentation is available atwww.liverpoollep.org/makingit.aspxproviding a range of resources to inspirethe creation of a global hotspot formanufacturing within LCR.

But the story does not end here. We know that there are many companieswho haven’t yet engaged with theMaking It process. There will be a rangeof views about what the future holds,and differing evidence as to where theopportunities lie. This document isintended to be used to assistconsultation to enable us to engage withcompanies across the City Region onwhat we might have missed and how wecan improve our approach. Full detailson how you can get involved can befound in Section 8.

The Making It Programme will look at the future of manufacturing, what we

make, how we make it and what we should be making in the future. This

follows a national Government-led exercise delivered by the Technology

Strategy Board. It brings together the LCR LEP, Liverpool John Moores

University (LJMU) and the University of Liverpool, the six local authorities,

and the Institute for Manufacturing, University of Cambridge (IFM ECS).

A key role of a university is to share expertise and research, thereby driving

business forward and contributing to wealth creation through innovation,

knowledge and technology exchange. That is why it is so important that LJMU

and the University of Liverpool are involved in this campaign.

Liverpool has always been an innovative City Region and now is the time to

work out how we can build on that innovation and establish ourselves as

market leaders once more. We are working closely with the private sector to

make sure that we develop the right plans for the future and offer the best

support to grow our manufacturing industries.

Universities in this City are set for the challenges of the 21st Century, using

education through research, scholarship and improvement of skills to provide

the right infrastructure to solve these challenges, including in areas concerning

the economy and manufacturing.

Vice-Chancellor, Liverpool John Moores University (LJMU)


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Liverpool’s Life Sciences University Technical College (UTC) provides14 to 19 year olds with specialist scientific and healthcare education


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VISION

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Manufacturing has always been at theheart of the City Region’s economy fromour excellence in ship-building to ourcurrent world-leading position inchemicals, vaccines or pharmaceuticalsthrough to the production of one of theworld’s leading motor vehicles.Sustained investment has contributed tocommercial success and a commitmentto produce innovative products whichrespond to economic, social and culturalshifts and changes. AdvancedManufacturing combines industry leadingtechnical knowledge, expertise increating products, production processesand supply chains which can bring asustained growth and an environment tofoster high economic value in the CityRegion and beyond. The aim now is tokeep LCR ahead of the globalcompetition and create a world leadingAdvanced Manufacturing environment.The first step of the process is toestablish a shared vision for the CityRegion. This has been done inpartnership with stakeholders across theindustry at every level of the supplychain.

We can become a global hotspot. A manufacturing environment with fouror five clusters of excellence – with onefrontier industry – could provide aframework to produce high value goodsand services. LCR leads in productdesign in a variety of sectors includinghealth and diagnostics. It is wellpositioned to take advantage of jobsreturning to the UK as reshoringcontinues through technology such asadditive manufacturing, 3D printing,training and skills. By identifying trendsand behaviours in society, cross sectoropportunities will arise that canencourage new supply chains. Our ever-growing number of SMEs will drive ourcapacity as well as the number of highvalue opportunities in manufacturing.

We need to attract the very best inbusiness, investment and people.Manufacturing needs to be smart, to beof high value and also good for theenvironment. To maximise this, supplychains must be agile and adaptable tomake the most of cross sectoropportunities. Knowledge sharing andbest practice must be a key behaviour.New skills and a sustainable, self-sufficient workforce are vital.

A capability for a self-funded growthexits in manufacturing. This provides thefoundation for a stable planningenvironment.

It allows the LCR to develop a capabilityfor managing the supply and demandaspects of its skills pipeline. There is self-belief and confidence in our innovationpotential which runs at the core of ourpractice.

Our culture is at the heart of our capacityfor growth. To empower this environmentof innovation manufacturing must beunderpinned by a well-founded sense ofcommunity. There must be individualaccess to skills and qualificationsenabling the regional availability oftechnical and graduate level skills. In thelong-term the strategy must reflect theneed for a growing collaborationbetween academia, government and themanufacturing industry itself. Investmentmust be secured. To help achieve this,and to attract the best individuals to thesector, there must be a redefinition ofwhat manufacturing means.

We have a shared vision for whatAdvanced Manufacturing should be inLCR. Our next step is to identify thelandscape and opportunities for growth.

LIVERPOOL CITY REGION:

A global manufacturing hotspot with the smartest networks, talent,technology and investment


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Jaguar Land Rover’s Halewood Operations plantis at the forefront of automotive manufacturing


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MANUFACTURING

LANDSCAPE 4

Advanced Manufacturing is a majoremployer, industry and contributor to theLiverpool City Region economy. Yet weknow we don’t exist in a vacuum. Manyof the trends and drivers shaping andinfluencing our industry impact on thenational and international picture. If we are to seize the opportunities ahead and prepare for any challengesand threats we need to understand theglobal and the UK picture, before weturn to our own landscape.

The Global PictureThe past thirty years has seen asignificant shift towards a moreglobalised manufacturing economy andthis looks set to continue into the future.The growth of economies such as Brazil,Russia, India and China, and especiallyincreasing wages will drive a growth inconsumer demand. Emergingeconomies present significant untappedconsumer markets.

Supply chains will continue to befragmented and international in scale,reinforcing the importance of logisticsand good networks. Finally, the drivetowards lowering costs of productionlooks set to continue, meaning the LCRwill meet stiff competition from lowereconomies.

The National PictureThe process to gain a comprehensiveunderstanding of the landscape and aroadmap for sustained growth inAdvanced Manufacturing is based onwider national practice.

In the UK, High Value Manufacturingrepresents a sustainable growthopportunity with long term benefits.Companies must focus on theeconomic, the social as well as theenvironmental impact and results. With a wide consultation with themanufacturing industry nationally,academia and institutions, the keysectors emerging on the national stageinclude:

• food• biotechnology• chemicals• pharmaceuticals• medical• aerospace• defence and space• automotive• rail• marine (including under-sea)• nuclear• energy• oil and gas• mining• built environment• electronics• digital economy

Five themes have been identified to formthe backbone of the national strategy.

• Resource efficiency, against thebackdrop of a scarcity of energy andother resources, this will impact on theUK manufacturing sector. Exploiting alow carbon market, reducing the useof energy and securing materials willbe increasingly vital.

• Manufacturing systems must be moreeffective and efficient. This can makethe sector globally competitive as itstrives to maximise its manufacturing technologies.

• To truly realise the potential ofinnovation new materials must beintegrated. Original products, newmaterials, coatings and electronics areat the heart of new manufacturingtechnologies. Bridging the innovationgap is a vital process.

• The manufacturing process itself must be more agile and cost-effective.This is set against a backdrop of anageing workforce and an increasingskills shortage with a low mobility.Investment must focus on themanufacturing workforce. Thenecessary skills must be built andyoung people must be attracted tomanufacturing.

• To create superior value systems, new business models must berealised. This will help to exploitinnovation and to capture value.


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Mapping the future

Trends and drivers were highlighted fromdiscussions and consultations thatidentified the principle challenges andopportunities in wider society that wouldimpact on Advanced Manufacturing. At the top of the chain is the increasingcost and scarcity of power and energydriving the importance of the security forsupply, the need to use fewer materialsand to use less energy – including water– for all outputs. Increasingly there will bea reliance on renewable resources.Resources include people as well asproduct, and an ageing UK workforcecontributory to a skills shortage. To makethe sector as competitive as possible,manufacturing needs to be able toinfluence and adapt to evolvinggovernment policy, tax and regulations tomaximise competitiveness. This includessustainability.

A major trend for manufacturinginternationally has been the movementeast. As resources diminish, transportcosts will increase, encouraging re-patriation and onshoring. This offers anopportunity to raise the profile andpotential of manufacturing in the UK.

Change, Innovate and Compete

R&D and innovation must remain agovernment priority. Emerging newindustries like photonics and renewableenergy offer strategic opportunities forglobal leadership by UK business,especially in multi-disciplinary areas.

Affluence will increase the pace ofchange. Post-recession and economicdownturn, a renewed confidence anddesire for growth will fuel innovation.

While onshoring offers an opportunity, the risk to the SME level of a decliningUK based supply chain contributes to ashortage in both skills and finance.Accessing finance and credit willincreasingly impact on policy timeframesat both an industrial and a political level.

A changing consumer

The rising ‘digital economy’ affectstraditional products, services andprocesses as well as creating newdemands. Manufacturers will need tomeet this and stay ahead of the shiftingtide to remain competitive and current.Producing in the UK could incur a highcost of production which may affect costfor the consumer and thus theirpopularity. The growing and ageingpopulation will increase demandimposing a challenge for health, socialcare and food.

Across the manufacturing sector, the study identified the need forcommonalities and shared technologyrequirements. Light-Weighting is not justa factor for the automotive industry; thisnew technology can create more cost-effective value chains, reducing relianceon resources. These developments neednew design, new technology and newmaterials.


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National competenciesA competency is an attribute of themanufacturing industry that enablesbusinesses to respond to changingglobal trends and drivers in a way thatcaptures value for the future economy.Competencies tend to impact across arange of sectors, for example goodprocessing skills will be important in bothautomotive and the food industry.

To achieve High Value Manufacturing themost significant needs are newproduction processes, driven by scaleand economy. Manufacturing needs tobe flexible and responsive to seize suchnew opportunities.

Intelligent systems make process asefficient as product. Data processing andstorage is important to streamlineprocess and create cost-effective valuechains, especially for SMEs. Newcomposites create the opportunity fornew products while alternative and bio-based sources for existing products andprocess materials as well as organicmaterials for electronics applicationsreduces the reliance on resources.Systems modelling and simulation(including prototyping) revamps andsimplifies the design process of newproducts, increasing its accuracy. Newpower sources reduce the reliance ontraditional energy supplies coupled withan increased use in products from wasteand virgin biomass.

New high performance materials workharder and create cheaper productionmethods. Light-Weighting in both designand manufacture is a vital new trend tobe tapped into. The focus must be ondesign to produce an improved andintegrated systems design focusing onreducing waste.

Contributors to the study and nationalconsultation were asked two questions;which manufacturing processes andsystems are going to be most importantfor the UK in the 15 to 20 year periodhighlighted and why? And what are themost promising emerging science,engineering and technology innovationswhich would address these trends andchallenges for the UK manufacturingbase and why?

The most significant process and servicetechnologies identified included:

The most significant product and servicestechnologies included:

Additive manufacturingNet shape manufacturing Robotics and automationCustomisation Small run technologies (including distributed manufacture and ‘batch size of one’)Micro and nano-manufacturing processesEnd of life activities: recycling, re-use, renewing and re-lifingSurface engineering (finishing and coating processes)Link design and manufacturing more closelyIntegrating technologies and processesBioprocessing for new/replacement materials/fuelsICT and enabling ICT structures

Materials and materials science (excluding composites)Low carbon technologiesLight-Weight materialsBiomaterialsSensor technologiesIntegrated technologiesNanotechnologiesEnergy storageHydrogen fuel cellsRobotsIntegrated products and servicesNew compositesNanomaterials


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Throughout the Making It process,business, academics, and individualsrepresenting different industries inAdvanced Manufacturing shared theirthoughts and reflections on trends andcompetencies that exist for LCR.

The landscape in Liverpool City RegionWe know what the trends are globallyand internationally. Locally, we mustrecognise and understand the nationallandscape but also identify thechallenges and opportunities that impacton us locally, and will continue to in thenext 15 to 20 years.

We have divided our predictions andinterpretation into three periods; theshort term up to 2017, the medium termfrom 2018 to 2025 and the long termfrom 2026 to 2030.

The growth of emerging markets like theBRIC nations and Asia pose both anopportunity and a threat; it raises thepotential of new clients but alsocompetition. LCR must maintain itsedge. We need to be able to identifywhat products, practices and processesbusiness will come to our manufacturingsector for because they will be unable tofind them anywhere else.

These following issues were identified bymanufacturers for the LCR.

The shortage of resources affects us now and in the future

The financial crisis has meant there isreduced funding and investment, in bothpublic and private sector, there is lessmoney to spend. Couple that in the shortterm with continued uncertainty over theprice of oil and a prime concern isresource. This affects the transport ofgoods as well as the use of rawmaterials in creating products.Manufacturing wants to be moresustainable so there is a desire for lowcost travel, for light-weight vehicles andfor simpler transport infrastructure relyingless on costly oil. Systems need to berefocused so that every layer of thesupply chain supports this ambition.

In the next five to ten yearsmanufacturers predict resources will bediminishing, leading to a greater impacton the sector itself and this trend willcontinue. LCR needs to be makingchanges to its processes as well as itsproducts to meet this trend.

Retail entertainmentand consumer goodsDigital entertainment, smart clothing

BiotechnologyDiagnostic toolsInfectious and microbial disease treatmentsBio manufacturing

PharmaceuticalsAnti-infectives,pharmacogenetics

ElectronicsSmart clothing andtextiles, sensor printedelectronics, bio-personalised products

Aerospace /Defence / SpaceComposites, sensors.Unmanned Aerial VehiclesUAVs

NuclearA closed reactor clean-up service


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Sustainability, in people and product

Over the next decade an ageingpopulation will have a serious affect onthe skilled population and those workingin manufacturing but also the productswe need to invest in. Medicine andproducts designed to support end of lifewill be increasingly important. Building ayoung, skilled manufacturing andengineering workforce is vital.

More green legislation is expected in thecoming ten years. More consumers willlook for green products and solutions.Therefore, it will become important topromote sustainable credentials, to beahead of the trend. Cities will grow insize, putting even greater pressure onresources for cities like Liverpool.Buildings themselves will need to bemore sustainable to meet both thegrowing population but also greenlegislation. At a city, regional, nationaland international level we will need to bepart of the solution and discussion aboutworking in a more sustainable way andmeeting demand.

In the longer term as we look 10 to 15years into the future there are a numberof trends we can predict will impact onour work in manufacturing in LCR.Personal carbon taxes and the individualfootprint will become more and moreimportant so there will need to beproducts and a transparency of processto match. Many products will be bio-based. If we invest now in research andproduction we will be able to lead theway. Water scarcity will mean a need fortechnologies to help business tocontinue operation with new products toease the transition.

Changing consumer requirements

Personalisation is vitally important formanufacturers. The individual and theconsumer desire to shape practice andculture around oneself is a trend that willcover every sector from choosing carsand gadgets to genetic medicines, smartclothing and person specific treatments.Personalisation and the power of theconsumer will define how manufacturerscommunicate with their customers aswell as the technology we invest in.

Innovation is key

Advanced Manufacturing presents anopportunity for improved quality of life. In Healthcare, IT and consumer goodswe can push frontier technologies tocreate decentralised consumerapplication. Digital technology is a majorfactor in this shift of focus.

The cloud, mobile and miniaturisationtechnology is an area that encompassesboth the drive for sustainability as well ascutting edge futuristic innovation.

Moving into the medium-term and interms of technology there needs to bestrength in design, disassembly and endof life products. Recycling, reusing andrepurposing; this taps into the need forsustainability. Electronics need to fuelconnectivity, building a partnershipbetween industries, clients andconsumers.

In the long term we will need to focus onwhat this means for plants andprocesses when the time comes toupgrade. The groundwork andpreparation must already be done if weare to seize new opportunities.

Built environmentMulti modal logistics, sustainable buildings, bio-manufacturing

AutomotiveComposites, low carbon solutions,sensors and detectors

EnergyWaste recycling, offshorewind Combined Heat andPower (CHP) plants, carboncapture and storage

MarineCarbon fibre ship building, offshoresupport and services for supply chains

Digital economyMulti modal broadband and communications

FoodFood diversificationInnovative food distribution methodsAgri-science

ChemicalsBulk chemicals, petrochemicals, advanced material chemistry

Bio processing


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SHORT-TERM

OPPORTUNITIES 5

Centre of Excellence in Light-weighting

The core of LCR’s offering in light-weight manufacturingis the automotive industry, where an increasing demandfor greater efficiency combined with high performanceis driving the market. Light-Weighting has wideapplicability across the automotive, marine, nuclear andaerospace industries, anywhere efficiency andperformance demand materials innovation.

To excel, LCR needs to move beyond its currentcapability to manufacture light-weight product, butbring together research, design and production tocreate a market niche, as well as the skills and supplychains required to advise and attract internationalattention.

The identified first step is the creation of a physicalfacility to act as an identified hub or ‘attractor’. This willrequire investment, but is well-aligned with the UK’sambition and the LCR potential has been stronglyendorsed by industry partners.

Global beacon for smart, non-invasive monitoring

From healthcare to engineering, smart monitoring isalready an established feature of product design,development and manufacturing. Linked closely withbetter IT, customers are demanding a greaterunderstanding of product performance. Examplesinclude embedded sensors in batteries for hybridvehicles, printed sensors on substrates, motion sensorsin the building industry and within NHS, procurementfor implants, wound management and infection control.

The future is increasingly converged between nano-technology, bio-technology, information technology andconventional electrical engineering. LCR is alreadyleading the way, with patents across a range of sensingtechnologies, which align well with the existing LCRmanufacturing base in automotive, bio-medical,maritime and digital industries.

The critical next steps include the validation,acceptance and scale-up of sensor technologies andmanufactured products, and the demonstration of useswithin target sectors.

Six short-term market opportunities, from a wider list of projects have been identified as part of the Making It process.

These opportunities are founded in the LCR’s existing strengths and asset base. These are either areas where we have

leading technology, companies, researchers or facilities; or where known investments will drive a new market

opportunity over the next 2-5 years.

They all also drive wider market trends. The key aspect of each of these opportunities is that they will drive the

establishment of core competencies required for longer term success of the LCR manufacturing sector.

To drive competency developmentand create competitiveness


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National Process Scale-Up Solutions Centre

The wider industry trend driving the need for enhanced‘scale-up’ solutions is personalisation. As productsbecome increasingly bespoke, manufacturers need tomove quickly to develop customisation processes andthen to quickly commercialise these bespoke products.A number of LCR manufacturers identified opportunitiesfor growth if the right solutions could be found; withsolutions likely to come from other industrial sectors, or from within the research sector more widely.

At one level, the Solutions Centre is a very pragmaticproposal that would allow for short-term problemsolving. Longer-term, the Centre provides a model for innovation, a network for cross-industry working,and a platform for new research investment

Liverpool City Region: Sustainable EnergySolutions

Over the next five years, LCR will see substantialinvestment across the energy sector. The Liverpool CityRegion LEP’s Action Plan for Low Carbon providesmore depth to these investments, off-shore windinvestment, waste-to-energy plants in some of thearea’s largest manufacturers, and research required fora Mersey Tidal scheme creates a powerful supply chainfor research and technology application. This is inaddition to the general market demand to lower energycosts and become more sustainable. Investment insustainable energy solutions is strongly backed by thelocal manufacturing sector, with the identified first stepsto focus on local energy generation, capture skills andcompetencies in power management, and invest inlocal energy infrastructure.

Northwest Shale Gas Exploration Platform

Shale gas exploration remains a controversial issue, and LCR, like many other areas is still to agree a wayforward. However, it seems probable that the Irish Searegion could provide one of the richest sources of ShaleGas in Europe, and consequently the potential todevelop an industrial platform for jobs, investment andgrowth.

To capture this opportunity, early intervention is requiredto understand the size of the opportunity, the requiredtechnologies, skills and suppliers, and to position LCRas a hub from which the industry could grow. It will beimportant also to understand the associated risks andcommunicate clearly with local communities,understand the regulatory environment, and capturevalue from associated procurement opportunities.

International Exemplar for Marine Ballast WaterTreatment

Ballast water is sea water carried by a vessel in itsballast tanks to ensure balance and structural integrity.When a ship docks, ballast must be taken on ordischarged, with obvious implications for the marineenvironment.

Local demand for treatment facilities, driven by thedevelopment of Liverpool2 (the new deep sea containerfacility in the Port of Liverpool), will increase as largervessels (both cargo and passenger) dock in the Mersey.Physical development zones on either side of theMersey provide potential locations for new facilities.Combine this with the LCR’s already outstanding offerin maritime research and professional services, and thepotential exists for world leading exemplar in a globalmarket issue that affects maritime, food, automotive,aviation, and the visitor economy industries.


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Skills training provision must meet the needs ofLiverpool City Region’s advanced manufacturers


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LONG-TERM COMPETENCY

DEVELOPMENT: 6

Light-WeightingCreating light-weight vehicles does notsimply ensure a faster mode of travel. It also reduces the reliance ondiminishing resources, meets regulatoryand consumer demands for increasedefficiency whilst improving performance.Intertwining innovation with sustainability,the production of light-weight vehiclesacross the automotive, marine, nuclearand aerospace industries can fuel theambition of an industry to reduce itsreliance – and that of its customers – on carbon energy sources. Research,design and manufacturing creates aniche and highly sought after skills setwhich could elevate the already globalreputation of LCR’s automotive industryto a world-leading platform.

The design and manufacture of light-weight vehicles is cross-sector as well as cross-motivated.

The use of innovative materials likecarbon fibre makes a vehicle lighter, able to travel faster and use less fuel. For consumer facing manufacturers this meets the need for more efficientvehicles. For manufacturers tasked withgetting products from a to b it reducestheir overheads and travel time andcreates a more efficient infrastructure.

LCR and the wider North West is alreadyrecognised as one of the world-leadingcentres for automotive design and build.From Jaguar Land Rover to Vauxhall inEllesmere Port to Briggs AutomotiveCompany (BAC), the sector is poweredby keeping ahead of the curve andcombining technology with consumerneeds and demands.

Outside of the automotive sector, light-weight vehicle manufacturing impactsmarine and infrastructure, set to be

increasingly significant over the nexttwenty years with SUPERPORT andHS2. As an historic gateway to theworld, embracing the latest technologyfor vehicles can combine the CityRegion’s transport ambitions with itsmanufacturing sector.

Light-weight capability would help toencourage continued large scaleassembly of wind farm components. It would build on a capability forspecialised small scale marinemanufacture and the creation ofautonomous vehicle manufacturing forthe nuclear, ports, defence and medicalsector.

In the short to medium term it isimportant to engage with the NationalComposites Centre, both through LEPand externally. In the long term theambition must be to make the LCR theplace for core skills and competencies.

Intelligentsystems &embeddedelectronics

Smart, hybrid &multiplematerials

Energygenerationmanagementsecurity andstorage

Developing and retainingskills tosupport High Value

Manufacturing

UnderstandingDesigning andManufacturingformulatedproducts

FlexibleAdaptive andScalable

Manufacturing

Design andManufacture forLight-weightvehicles andstructures

Managingfragmentedvalue chains

Biological,BioTech andSyntheticBiology

processing

SystemsModelling andintegrateddesignsimulation

Automation,Mechanisationand HMI

Developmentand applicationof advancedcoatings

New BusinessModels

Big DataMaterialsInnovationFactory

QuantumTechnology

Globally CompetitiveCompetencies(building blocks for the future. 10 yeardevelopment cycle)

City Region has identified opportunities that align with national strategic requirements

LCR competencies which align with Nationally desirable competencies Strengths in addition to national framework

Building blocks for the future


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The world's first road-legal, single-seater production car is the BAC Mono manufactured in Liverpool


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BAC (Briggs AutomotiveCompany) Ltd is a British sportscar manufacturing companyopening a new production site atSpeke Hall Industrial Estate,Liverpool.

BAC Mono is the world’s first road-legal single-seater production car.Awarded GQ’s Track Day Car of theYear 2012 and in the same yearawarded Top Gear’s ‘Stig’s Car of theYear 2011’ the Mono has inspiredmotor enthusiasts and manufacturersalike. BAC founder Neill Briggsdescribes the supercar as combing “a purity of design, zero compromiseand high performance”. Innovation in technology, he says, is vital. “The Mono exemplifies the purestsupercar which rejects convention andornamentation but instead is designedpurely for function and beauty in form.Its appearance is unparalleled and itmeans business, both in terms of howit looks and in performance.”

Heralded as a revolution from a design perspective, the Mono refusesto compromise on design andperformance. New materials for Light-Weighting, like carbon fibre and aluminium allow for the potentialto scale up facilities for a high volume composite manufacturing.“We use wood which is nature’s bestcomposite for the floor materialswhich is impregnated with awaterproof membrane, aircraft gradealuminium, carbon fibre on 44 partson the interior and exterior of the car,stainless steel and coal drawnstainless steel.”

Fuelling the drive to encourageadvanced manufacturers in LCR toinnovate with new materials, light-weight vehicles is a smart conceptthat builds a sustainable infrastructure.It develops the skills pipeline,increasing the ability of LCR to attract new firms like BAC Mono.

This focus on innovation may begin atthe elite of the car world but it filtersalong the supply chain. Briggs added“The supercar sits in a unique place incar manufacturing. Its price pointallows traditional manufacturers tospend money on research,aerodynamics, new materials etc. That feeds into cars on the road. Thinkof the S Class Mercedes of 20 yearsago. It featured ABS brakes, activeride control, curtain air bags andenhanced safety and performancethat, by and large, has now filtereddown to the cars everyone drives.”

NGF EUROPE Limited is asubsidiary company of the NSGGroup of Japan, one of the world'sleading manufacturers of glassproducts for building, automotiveand information electronicsapplications. Situated in St.Helens, NGF EUROPE is at theforefront in the manufacture andmarketing of specialised GlassCord products. Alistair Poole isManaging Director:

“What we do is very niche andtechnical. Our products have severalapplications but the major one is asthe reinforcement in a timing belt forcar engines. The glass cord made byus relies on the strength and flexibilityof glass fibres to carry the load fromone part of the engine to another. The belt, used instead of a chain,reduces emissions and is quieter.”

The glass cord is manufactured with a variety of coatings designed tomatch each customer’s requirement.The complete coating of individualfilaments of glass yarn with specialbespoke resorcinol formaldehydelatex (RFL) formulations compatiblewith a large number of rubbercompounds gives the product “life ofengine durability” – up to 300,000 km.It is strong, flexible and durable.

A new technology in 2006 is just now coming to commercial fruition.Normally the belt runs outside anengine in the dry whereas the chainruns in the oil in the engine. TheGlasscord® ‘Belt in Oil’ timing beltsystem uses an innovative materialthat allows a car’s main engine drivebelts to be immersed in oil withoutdegradation.

This innovation results in reducedfriction, noise and vibration andmakes for a more efficient engine. The new technology features in theFord Eco Boost Engine launched in2011 which achieves a 20% betterfuel efficiency and 15% reducedgreenhouse emissions. It has beennamed the most eco efficient enginein 2012 and 2013.

Case Study

Case Study


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Backed by local expertise, pharmaceutical and life sciences manufactureform an important part of Liverpool City Region’s Knowledge Economy


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Case Study

Mast Group, based in Bootle, is a manufacturer of In VitroDiagnostics, or out of bodytesting. Specialising in InfectiousDiseases and Microbiology,Mast’s primary market in the UKis NHS Hospitals with ClinicalLaboratories.

With the NHS consolidating itsservices and the market itselfbecoming more regulated, Masthas developed the Isoplex test, a diagnostic product drawing ontheir experience of molecularbiology.

In emergency care in hospitals, or GUM clinics there is a need fordiagnosis to be quick, cost-effectiveand as simple as possible. Isoplexuses just one sample and managesboth the DNA extraction andamplification. In an hour, a correctdiagnosis can be delivered and thepatient can begin receiving thecorrect treatment immediately.

There is a growing trend forpersonalised medicines as well as theneed for hospitals to have a moreefficient diagnostic procedure.Increasing resistance to antibioticsimpacts on the spread of disease.Focused treatment delivered rapidlyhelps to reduce this risk and is betterfor patient health. Powerful antibioticscan have side effects, minimising theneed for incorrect treatment causedby delays in diagnosis are minimisedby Isoplex.

For GUM clinics that treat patientswho come in from the street, a quicker diagnosis removes theexisting process where samples aresent away and finding the patientonce diagnosis occurs to begintreatment can be difficult.

Biology and BioprocessIn LCR the chemicals andpharmaceutical industries are focused on shifting trends and technologies.Personalisation is a trend with thecapacity to transform the industry.International firms are looking toresearchers, to manufacturers and SMEs to help them service their ownclients within the health industry. An ageing population, one of the corechallenges facing manufacturing andsociety in the coming generation, willneed this technology to counter theincreased cost of on-going treatment aswell as a growing reliance on health andsupport services.

In research and development both in thepublic and private sector the short termfocus is on making diagnosis easier byimproving the tools used in healthcare. In five to ten years the principal aim is todevelop treatments for infectious andmicrobial diseases.

As with each corner of manufacturing inLCR, facing reduced resources of energyand funding is a significant challenge.The design and manufacture of productsmust focus on sustainability andthrough-life, reducing the need forreplacements which place a greaterdemand on resources.

Creating innovative products using newchemicals, materials and coatings is animportant element of keeping the sectorcompetitive. What is important is quality,customer expectation and the need fornew products.

Updating processes throughout thechemicals and pharmaceutical sector in LCR will make it leaner and morecompetitive. To focus on innovation andexplore new technologies like macroalgae based production, to facilitate bio-processing for new vaccines ortissue engineering and regenerativemedicine there has to be an acceptedculture shift at every level of the supplychain. The industry needs support if it isto champion the drive towardsinnovation through the NHS.


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Powering the futureEnergy is at the core of manufacturing.Its generation and the development of asustainable energy strategy and policywill define how the manufacturingindustry evolves in the face ofdiminishing resources. For the next five,ten and 20 years much of the attentionof the industry – from R&D to sectorleaders – will be focused on how tomanage energy, how to secure its supplyfor business and consumers and toembrace renewable alternatives andreduce the impact of manufacturing onthe environment.

Green legislation will impact on designand production across the industryincluding transport, reinforcing the needfor innovation. Sourcing sustainablesolutions to minimise the disruption ofthe supply of goods means investing inalternative energy.

Geography is a major factor in LCR’scapacity to be at the core of an energysolution. On the coast of England withthe Irish Sea to the west and excellentlinks to the Atlantic, Liverpool’s maritimeheritage is famous around the world. It needs to be brought into the 21stcentury. SUPERPORT, the ability toestablish LCR as a hub for the transportof goods via sea, rail and road can helpchallenge firms’ lack of finance making itcheaper to distribute goods.

Wave and tidal energy offer anopportunity to help reduce energy costs and the risk of supply distribution.Tidal resources could power the city aswell as other towns along the coast. The UK has half of the tidal powerresources for the whole of Europe, with Liverpool at the heart of it. There ispotential for research and developmentas well as manufacturing.

Reducing the reliance on carbon basedenergy sources is a vital area of researchfor manufacturers. This has businessimplications for the industry – in terms ofmeeting the requirements of greenlegislation and regulation - but also forconsumers and the ability to securesupply as resources diminish. Newsources of energy could reduce energyprices as well as manufacturingoverheads.

Waste energy is an important area ofresearch. Converting waste into a powersource would reduce costs and makeLCR and UK manufacturing morecompetitive against the USA and China.The energy supply would be moresecure and less reliant on anunpredictable global marketplace. Local energy generation would needmore concerted planning but it couldincrease the visibility of the City Regionat national energy requirement planning.

There is a need to incentivise local powergeneration. Funding opportunities couldsteer where investment and actionshould be taken.

Holistic carbon optimisation and thereduction of CO2 emissions throughsupply chains epitomises a statement ofintent which is motivated by a desire tobe more sustainable. This is the short-term. In the medium-term developingstructural composites could transformenergy storage. There are benefits forautomotive and transport. Smart EnergyStorage – including Combined Heat andPower (CHP) – can change therelationship of traditional manufacturingto energy usage.

Energy is not just a local issue but thereneed to be incentives for localgeneration. Tidal or nuclear generationcould power the manufacturing sector.There could be an opportunity for energymanagement to be conducted on a locallevel, perhaps through local economicpartnerships. The manufacturing industrycan explore and exploit technology topower this shift and commitment tosustainability but it needs direction.Central government needs to give a clearindication of what is expected from anational energy policy.


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ACAL Energy is an innovativechemical company developingand licensing a ground-breakingplatinum free liquid catalyst,FlowCath®, and is the world'sleading developer of low costProton Exchange Membrane(PEM) systems used to power fuelcells. ACAL Energy is based inRuncorn.

ACAL Energy, is very much a part ofthe power generation trend forrenewable and zero-emission fuelsthat can match (or ideally out-do) theirfossil fuel counterparts. There are twostrands to this trend: the first is energygeneration, and the second is energystorage.

Energy generation is what hydrogenfuel cells are all about – fuel cellsmake their energy from a chemicalreaction with two very commonelements – hydrogen and oxygen is allthey need. For car manufacturers thisis very interesting, because a fuel cellcar can get its fuel from a pump inunder five minutes and can do over300 miles on a single tank.

The ultimate goal is an electric car that drives, handles and re-fuels like a traditional car. That’s why so manymanufacturers (Nissan, Honda,Hyundai, Toyota, Daimler, BMW, Audi,Ford and GM), are all launching fuelcell vehicle platforms over the next 2-3 years.

On the energy storage side, one bigissue for providers of intermittentgreen energy - that is anything thatdepends on the weather to work - is that supply and demand are notalways in synch. One option is to turnpower into hydrogen, via electrolysers,so it can be easily stored as a gas,then re-converted back into electricityinside a fuel cell and fed back into theGrid. When size isn’t an issue, youcan get a huge power output from afuel cell because hydrogen is very‘energy-dense’ – one kilogram ofhydrogen has the same amount ofenergy as one gallon of gasoline, andtakes 40 kWh of electricity to produce(this is the same amount of energythat 60 average homes consume inone hour).

ACAL Energy’s FlowCath technologyis an enabling technology for fuel cellproducers as a means of reducingcost, improving performance, andenhancing durability, whilst at thesame time increasing the service life ofthe system. This is a unique offeringas no other technologies out therecan address all these issues at thesame time. Because ACAL owns theintellectual property, they constantlydrive to improve the chemistry anddesign.

Case Study


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Smart systems, smarter technologyIntegrating technology, innovation,design and manufacturing is what willelevate LCR’s Advanced Manufacturingsector above its global competitors.Through systems modelling, integrateddesign and simulation - reducing costsand timeframes for new products - to intelligent systems and embeddedelectronics technology it taps into widersocial trends, meeting the demands ofconsumers and producers alike.

Smart, hybrid and multiple materialsoperate across the manufacturingindustry, powering the automotive sectorand enhancing its ability to create cuttingedge vehicles, empowering drilling firmsto expand their infrastructure and explorenew energy sources. Technology is aleveller, enabling both small and largefirms to be at the forefront ofdevelopment. LCR is at the centre of aglobal advance in smart sensortechnology.

Systems Modelling, IntegratedDesign and SimulationEmbracing technology fuels innovationand design. Systems modelling andsimulation reduces the time andinvestment needed in new product andbuilding development and innovation. It enables designers and manufacturersto get from the drawing board to realitymuch quicker.

It is vital to create innovative products, to stay a step ahead incorporating thelatest tools, techniques and technologyavailable. New chemicals, materials andcoatings will help to drive this over thenext twenty years. The automotiveindustry, for example, is looking to smartand hybrid materials to usher in the nextgeneration of vehicles.

Intelligent systems and embeddedelectronics will drive towards the trendof personalisation, linking manufacturerswith consumer. For health, medical aswell as lifestyle and life sciences thistechnology offers the real potential toboth change and save lives. Smartclothing and sensors already tap intoLCR’s knowledge and thoughtleadership.

Liverpool John Moores University andMedePad collaborated on a patent toproduce wireless sensors able to monitora patients’ vital signs, like their heart rate,blood oxygen levels and temperature.Done without hooking the patient up to a machine the sensors are bothinvisible and undetectable to the wearer.A person’s readings are transmitted inreal time to devices located many metersaway. The smart sensor technologydeveloped by researchers at LJMU’sBuilt Environment and SustainableTechnologies (BEST) Research Instituteuses electromagnetic wave sensorswhich can be woven into fabric includinggarments and wristbands.

Wearable technology has wide rangingpotentials, not just for health but alsosport and the military. With an ageingpopulation, widening the application ofthese sensor devices helps incorporate acost-saving and efficient approach whichis also patient centric and personalised.


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Smart, hybrid, multiple materials

In Advanced Manufacturing the tiebetween research and production issymbiotic. As manufacturers increasinglywant to make more accurate products,elevating them from producing a goodproduct to a market leader for example,they turn to the technology researchers.At LJMU’s General EngineeringResearch Institute, work into 3Dmeasurement and processing ofcomposites offers a glimpse intofuturistic models of design andmanufacture.

As manufacturers pursue ever moreoptimal design, success or failure isdetermined by ever finer margins onoften complex 3D surfaces and this istrue at all scales – from the macro to themicro.

Inspection of highly intricate 3D surfacesat macro level is becoming increasinglyimportant, manufacturers need to notonly perform the task but integrate it withtheir design operations.

Research in this area holds out thepromise of one day having automated,high-speed, non-contact shop floorinspection via new optical systems thatpass that data back for comparison withthe original CAD solid model of the part.

In the automotive industry there is a drivetowards producing the composite car.Mass producing such a vehicle thatworks optimally, maybe still some wayinto the future, but for manufacturers likeJLR it remains an ambition.

Case Study

The General EngineeringResearch Institute (GERI) isbased within Liverpool JohnMoores University and is active ina variety of fields ranging fromoptical metrology, advancedmanufacturing technology, radio-frequency & microwave researchto electronics, image processingand mechanical engineering.

While 3D measurement offers anexciting glimpse into the future ofdesign and manufacturing at presentit has its limitations, Professor DavidBurton from LJMU explains, “It isdifficult in a mass market. It is in thetechnology where we are meeting thelimitations in both machining andjoining composites.”

To mass produce a car in this way ithas to be economically viable butprocessing composites is not yet farenough along the research processto be able to identify when it might bepossible to do this in a massproduction environment. “We needautomated ways of controlling andmeasuring both macro and microsurface features for compositematerials. Whether it is evolution orrevolution – a breakthrough – thatgets us there we don’t know.”

“It is in this margin where our futurelies,” says Professor Burton. “Themargin where we use technology likecomposites to not just be an also-ran, but a global leader.”


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The Virtual Engineering Centre at Daresbury Laboratory is one of the world’s foremost facilities


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Case Study

The Virtual Engineering Centre(VEC) was established in 2010with a remit to support theNorthwest aerospace sector andwider industry by providing afocal point for leading andemergent virtual engineeringtechnology, research andexpertise. A University of Liverpool,School of Engineering led project,the VEC is located at Sci-TechDaresbury.

The VEC has a unique capability in the UK providing a focus onharnessing the latest technologydevelopment, expertise, leadingacademic research and scienceinfrastructure to accelerate productdevelopment, drive productinnovation, quality and safety,reducing costs and time to marketacross advanced manufacturingsectors. VEC Director, Dr GillianMurray says: “What I’m most proud of is the work we have done to bringinvestment to the area. Having thebiggest supercomputer in the regionhas brought the VEC to the forefront;it’s encouraged a lot of inwardinvestment of companies relocatingfrom France and others within the

region taking over smaller companies.Small firms start to cluster and buildnew relationships which makes youbecome a bigger player in themarketplace.”

The VEC are constantly investigatingthe latest emergent technologies andresearch in advanced modelling,simulation and Virtual Reality appliedwithin an engineering and advancedmanufacturing context. Recentexamples include:

• working with Bentley Motors to evaluate and integrate new Virtual Reality technologies into their design process to speed up product development timescales, enable design modifications to be made at earlier stages in the process and before investment in costly tooling has been made.

• developing new workflows in collaboration with Jaguar Land Rover to optimise their modelling and simulation processes to maximise vehicle performance in pedestrian safety.

Dr Murray adds: “We’re breakingdown barriers using this technology.SMEs need dedication and they needsupport. Innovation can often be timeintensive for both big firms and smallones so we bring them both together,making it easier for both sides.”


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Flexible, scalable, adaptiveChange is coming. Manufacturing needsto be able to adapt to fluctuatingmarkets, to new innovations, technologyand infrastructure to remain cost-effective, agile and to remain on a pathto growth. By sharing knowledge andexperience, developing new models andprocesses LCR can help to strengthenits already modernised industry.

Understanding trends is a vital step inmeeting a need to stay flexible andscalable. Personalisation increases focuson the customer. Technology is theproduct which meets this need; processis the valuable culture to enable it. At every stage of LCR’s AdvancedManufacturing industry, SMEs are at theforefront of delivering innovative researchand ideas. By their very nature SMEs areflexible and scalable but to be able tocontribute effectively to the supply chain– and remain successful – they need tomeet distinct challenges. For newtechnology, finding a route to marketneeds support and investment. SMEslike Mast Group Ltd in Bootle respond toshifts in the global marketplace byinvesting in innovation, developingproducts to meet a shifting need. SMEsneed on-going support throughout theprocess from concept, design andmanufacture.

Understanding the customer moreeffectively, as well as understanding themarket as precisely as possible, is vitalfor manufacturers at every stage of thesupply chain if sustained growth is theultimate ambition. In the short-term,understanding the effects of regulationson the consumer and the industry,mapping raw materials, their usagealong with energy supply (together withprice) is at the core of shaping behaviour.If flexibility is the goal then a systemenabling a fast response helps to buildan increased capacity. A fast reactionmakes it easier to meet customerrequirements. To increase capacityfurther there needs to be easy access tofinance. Business planning and futureproofing can help prepare smaller firmsfor this shift in behaviour. R&D teams canbe involved to develop and modify theprocess.

In the long term this commitment toflexibility results in an ability tounderstand and adapt to technologicalchanges, to develop a skilled and trainedworkforce and work within a scalabletransport infrastructure. Back upsupplies of raw materials ensure nodisruption to supply. As capacityincreases then supply needs to meetdemand.

This is not a process to be done inisolation. Working cross-sector acrossLCR can empower and reduce thereliance of numerous manufacturersfighting for limited resources.

Technology, or cross-investment, isanother tool for creating cost-effectiveand efficient processes that makes asector more flexible and adaptive. Bothaerospace and the automotive sectorhighlight the potential of additivemanufacturing, or 3D printing, as animportant step for cutting costs.

Small-scale and miniaturisation will beincreasingly significant for thePharmaceuticals sector; cutting costs aswell as reducing the reliance onresources. Creating novel conversionprocesses for scale, economy andefficiency are important for Chemicals.

The benefits of growth and developmentneed be felt throughout the supply chain.To fully benefit, there needs to be a focuson building new business models torealise superior value systems.Fragmented value chains needs to bemanaged. The benefit of getting fromdrawing board to the road quickly andefficiently is vital.


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Case Study

CNC Robotics produce roboticmachining solutions for manydifferent industry applications andfor all ranges of industries andcompany sizes, from big bluechipcorporations to SMEs and otherentry level companies. CNCRobotics is based in Liverpool.Jason Barker explains howtechnology can revolutionise howa firm works, but that theinvestment is a majorconsideration:

“CNC machines are very good at whatthey do, what they are designed todo. But while the cost might be£100k, £200k or £400k the relativerobot could be £50k, £60k. There is asignificant saving with a robot. Untilfairly recently that saving has not beobtainable because there have notbeen the integrators to be able to usethose software toolpaths.

What we are doing is embracing aworld where the manufacturers arereluctant to spend any capital to buynew equipment. Their return oninvestment (with that new equipment)is higher, with a greater speed (tomake the product) and accuracybecause the robot we make is faster.We are creating a product that makesour customer’s products moreprofitable. They are streamlined,optimised and reduce their costs byintroducing this new technology.”

He adds: “From major firms to SMEs,the decision whether to invest intraditional technology or opt for a newmodel is a difficult one. These roboticsare cheaper to purchase but as abrand new technology it does nothave a track record.”

“When you talk about scalability wehave a raft of clients who all comefrom different backgrounds anddifferent areas of manufacturing; frombig blue chip companies to a pumpkincarver in the US and everyone inbetween. The same robot can makean aeroplane wing, can make an icesculpture, can make a pumpkin forHalloween. It’s the same technology,the same software it’s just theapplication that’s different. We marrythe customers need with theapplication. You can apply robottechnology to anything – that’s whywe’re one of the top 250 companiesin the UK.”


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Robots created and built in Liverpool City Region are transformingmanufacturing processes in numerous industries all over the world


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CAREERS IN

MANUFACTURING 7

Where is the future of manufacturing?The process of developing this roadmaphas seen LEP communicate with everytier of manufacturing in LCR. Workingwith employers the LCR has recentlypublished a Skills For Growth Agreementsetting out a plan for realising potentialand how stakeholders can make thishappen.

With every company, multinational toSME, producer to supplier one concernhas been raised time and again; how dowe create the skilled workforce we needto achieve our aim?

Innovation is at the heart of AdvancedManufacturing. Yet to fully embrace that,and to develop a sustainable strategy togrow and expand, we need a worldclass workforce to meet our world classambition.

Skills and education must be at thecentre of our roadmap because we findourselves facing a challenge. Our peopleare our most valuable asset. Yet ourworkforce is ageing. We are notattracting young, skilled workers tomanufacturing. 10% of the UK’s working population works in our industry, in LCR it is 13%. One in three of ourmanufacturing workforce is over 50. Just 11% is aged under 24, with just 3% aged 16-19.

33%

8%3%

56%

Aged 16-19 Aged 20-24

Aged 25-49 Aged 50+


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Local companies provide valuable support and practical experienceto students at Liverpool City Region’s University Technical Colleges


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A young and highly skilled workforce will generate more money for the local,regional and national economy. If we cancreate innovative business models andproducts in the North West we canbenefit the UK economy by an added£160m annually. Over ten years thatfigure rises to £1.33bn*.

Yet fewer graduates are turning toAdvanced Manufacturing. Employersvoice their concerns about the level ofskills among both undergraduates andgraduates. Some look abroad to Indiaand China to fill their vacancies. If LCRand the UK is losing out in terms oftalent and skills its manufacturingindustry will suffer. We need to attractthe very best candidates and we need toincrease the level of skills among youngpeople.

We have two separate goals;

• Improve the skills of young people tocreate an ambitious, talented andproficient young workforce capable ofcreating and contributing to a worldclass industry

• Make manufacturing an attractiveopportunity for young people

Manufacturing needs to be increasinglyinvolved in education. No longer canbusiness lament the quality of graduates;instead it must be involved to developthe workforce it needs.

Innovative programmes have beenestablished by manufacturers around theUK to inspire and invest in education. LCRcan learn from these and incorporate intoour own relationships between industryand educational outlets. Rolls Royce inDerby has a variety of education outreachprogrammes working with youngstersfrom the age of five involving practicaland process based initiatives inengineering.

Teaching young people about theopportunities in manufacturing, frombuilding jet engines to exploring how aproduct gets from the drawing board tothe back of a freight train, encouragesthem to see manufacturing as anemployment alternative.

Our industry needs to work moreholistically. Projects like the SharedApprenticeship Scheme can help toidentify excellent candidates andpromote alternatives to university.

Manufacturing needs to improve itsrelationship with university and furthereducation colleges. There needs to be apartnership between industry andacademia. This creates a more skilledand inspired workforce but also a moreversatile employer.

Manufacturers need to provide the rightenvironment for employees to learn anddevelop. To create world leaders in ourindustry we must develop the models forthem to succeed. LCR has theopportunity to become a world leader inAdvanced Manufacturing. We want tocreate a self-perpetuating crop ofexcellent young candidates inmanufacturing. We want internationalfirms to source new members for theirteam from our skilled young people. Thiswill not damage our own infrastructurebecause we will have created a machinethat is constantly providing the industrywith excellent young professionals.

The numeracy and practical problemsolving skills of 14-18 year olds needs tobe developed. Manufacturers know theskills they need. There should be greaterpractical project and processmanagement tasks within the schoolcurriculum.

The image of manufacturing

Creating a skilled workforce is vital formanufacturing but the industry alsoneeds to be able to attract the brightestand the best graduates.

The image of manufacturing needs tochange. This is an exciting, global careerwith creative opportunities and excellentpay. We need to encourage graduates tostay in manufacturing once they havefinished an industry-relevant degree. Weneed to encourage more young peopleto choose manufacturing as a career.

Communication with young people hasto start early, as young as five when theyare deciding about what job they mightwant to do. In secondary schooldecisions are made early about whichsubjects to take. Manufacturing needs tobe seen as a viable option before then.

Our sector needs to work with teachersto help them paint a more positivepicture of manufacturing.

We need to show graduates that this isan exciting sector with real potential.Along with the Manufacturing FuturesGroup we need to promote anunderstanding of what AdvancedManufacturing is and the careeropportunities for every graduate. We need to have an ambassadorial role to spread our message.

When manufacturing is represented inthe media we need to reflect a morecreative and aspirational industry. Too often the picture is of factory linesand the story is of a declining industry. We need to communicate positivemessages and provide pictures whichaccurately reflect the work we do.

* Liverpool City Region Skills for Growth: Advanced Manufacturing, 2013 (NWBLT, 2013)


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Low Carbon Energy opportunities including Off Shore Wind Farmassembly processes represent advances in manufacturing


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Throughout this consultation, we havesought to answer the following question:What is the future for AdvancedManufacturing in LCR?

Working through the Making It process,we have heard from some of LCR’sleading companies to map out the futureAdvanced Manufacturing landscape, and set out a clear vision of what LCRcan achieve. Our message here is clear. The CityRegion has modernised itsmanufacturing base and has developedan industry that is now vibrant and whichcan be globally competitive into thefuture.

To be so, we must focus on the longterm building blocks that will drive theindustry, and accelerate our short termopportunities as a mechanism for doingso. In this document we have set out a summary of what we think theseopportunities and competencies look like.

We now need to hear from you.

Are you a localmanufacturing company but haven’t yet had your say?

Are you a potential investor, looking to the future success of the LCR?

Do you work with AdvancedManufacturing companiesand can help us to build theworld’s best manufacturingenvironment?

8CONSULTATION PROCESS

The landscape

The vision

Short-term opportunities

Long-term competencies

Response and action

For further information go to www.liverpoollep.org/makingit.aspx or email us at [email protected]


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Energy generation, storage,management and securityEnergy storage, energy managementand transport focusing on energy cost,security and novel generation technology.New energy sources including nextgeneration nuclear and energytransmission with low loss and low visualimpact.

Biotech, biological and syntheticbiology processingAlternative bio-and synthetic bio-basedsources for new and existing productsand processes. Processing of biologicsfor pharmaceutical and medicalapplications.

Design and manufacture for light-weight vehicles, structures anddevicesLight-Weighting to reduce energyconsumption and emissions, reducecosts and increase efficiency. Composite,new and hybrid structures design,fabrication, joining and assembly.Multifunction component design andmanufacture.

Systems modelling and integrateddesign/simulationSystems modelling and simulation tools,integrated system design, simulation andvalidation. Virtual prototyping, materialsmodels, functionality and design. Systemintegration of high complexity products.

Automation, mechanisation andhuman/machine interface Process automation and human machineinterface. Autonomy applications,particularly in production and servicing.

Understanding, designing andmanufacturing formulated productsUnderstanding design and manufactureof formulated products for relevantsectors across the supply chain.

Smart, hybrid and multiple materialsDesign, modelling and manufacturingprocesses of multi-metallic componentsand high performance materials.Structures and components withintegrated functions and tailored materialproperties and location-specific properties.Enhanced, faster joining capability with arange of materials.

Intelligent systems and embeddedelectronicsRobust ‘live’ data capture andcomprehensive capture and use ofproduct/process information. Newsensor/NDT devices and smart andmulti-functional components which areembedded and/or intelligent. Large area,printable, cheap electronics, integratedwith other manufacturing processes forenergy management, security, packagingand light weighting. Integration of electronicsinto product and materials design.

Development and application ofadvanced coatingsDevelopment and application ofadvanced coatings across multiplesectors.

Flexible, adaptive manufactureFlexibility of production and manufacturingsupporting customised and rapidlyreconfigurable manufacturing. Adaptivemanufacturing including single step,flexible reconfiguration and processtechnology that can adapt to feedstockof different types and compositions andmass customisation techniques.

Managing fragmented value chainsto support High Value Manufacturing(HVM)Managing complex value delivery acrossthe value chain in multiple locations andexploiting ‘economies of small scale’ todevelop and produce close to thecustomer.

Building new business models tosupport High Value Manufacturing(HVM)New business models, with flexiblearrangements to create new value.

Developing and retaining skills tosupport High Value Manufacturing(HVM)Associated training and skills in HVM,provision of employees with cross-disciplinary skills and the ability tocombine knowledge.

9COMPETENCY DEFINITIONS

Image credits: Dupe Creative, Terry Mealey, Jill Jennings, Siemens Press Pictures @ Siemens AG, Cammell Laird, Mast Groupand LEP image library.


Advanced Manufacturing systems are among engineering courses provided by the University of Liverpool using technology, management, systems and their integration to create competitive, value-adding operations.

FURTHER INFORMATION

Contact

Alan WelbyExecutive DirectorT: 0151 237 3907M: 07833400654E: [email protected]

LiverpoolLEP.org/makingit

advanced manufacturing in liverpool city region manufacturing in the uk. lcr has adopted this...

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