Our Work

At HSSMI, our work is often required to support organisations across several key areas. We have helped develop strategies, business cases and designs to build new production capacity whilst implementing opportunities to increase sustainability and resource efficiency for organisations.

Additionally, as part of our consultancy services, we develop roadmaps for businesses to respond to the challenges and opportunities for digitalisation, whilst we champion the introduction and effective use of new technologies within the UK manufacturing industry.



The aim of the Electrified Powertrain Pilot Line for Manufacturing Engineering (E:PrIME) project is to create unique capabilities for ultra-high-volume manufacture of next generation powertrains. The consortium consists of the manufacturing engineering and machine tool builder supply chain of these new powertrains with the aim to develop new processes and test them at rate whilst integrating new manufacturing concepts based on Industry 4.0.


Project VALUABLE’s key objectives are to develop commercially viable metrology and test processes as well as new supply chain concepts for recycling, reuse and remanufacturing of automotive lithium-ion batteries to create a complete End-of-Life (EoL) supply chain network within the UK.




Hydrogen Diesel Injection in a Marine Environment (HyDIME) aims to make waves in the marine industry by proving the safe integration and use of hydrogen on vessels. One of HyDIME’s goals is the design and physical integration of a hydrogen injection system on a commercial passenger and vehicle ferry which will be the first of its kind worldwide. The hydrogen used in the HyDIME project will be cleanly produced from renewable energy.



The Closed Loop Innovation for Fused Filament Fabrication (CLIFFF) project focuses on developing a new value chain from a plastic waste stream. The project is novel as it aims to develop a reverse logistics system for collecting waste from a targeted and growing 3D printing industry.



Intelligent Naval 4.0

The IN 4.0 project aims to improve the competitiveness of naval sector companies through the adaptation of the traditional productive model towards the Industry 4.0 - guaranteeing the sector’s endurance in an increasingly demanding market where technological innovation is a key factor of strategic advantage.


Pilot Kitting Robot - PIKBOT

This Pilot will build a robotic test cell that enables Nissan Motor Manufacturing UK to develop automated kitting capability for its part families. The cell is intended to be modular and scalable built on low cost, commercially available hardware integrated together with advanced software capability.



Holistic Immersive Collaboration

The project creates an environment for holistic immersive collaboration i.e. connecting multiple visualisation options to a central, company-wide digital knowledge pool. The objective of the project is to shorten the time to ramp up automotive manufacturing and reduce time to market whilst decreasing the cost of machine maintenance. The focus of the project is to develop number of augmented and virtual reality technologies along with a platform.



Factory Symbiosis

FactorySym project is an analysis of the workflows used to create Digital Twins, focusing on breaking the concepts down into parts, and using interchangeable software packages, rather than complete all-in-one solutions. The consortium included an automotive manufacturer, and simulation and IoT solutions providers. The aim is to make Digital Twin technologies more accessible to manufacturers, and integrate with existing systems, not replace them.


High Volume Additive Manufacturing - HVAM

The overall objective of this project is to deploy High Speed Sintering technology (HSS) in a high-volume series production environment. The project aims to develop a decision-making tool that will be used to compare and contrast additive manufacturing against conventional manufacturing techniques and provide a systematic process of material selection.



opendynamic Manufacturing Operating System

Opendynamic Manufacturing Operating System (openMOS) was a European project with a consortium of 15 companies which developed a modular plug-and-produce equipment. The objective of openMOS was to allow quick integration of machines and automation systems in production environments, a prerequisite for the implementation of Industry 4.0 solutions. HSSMI delivered a genetic algorithm optimiser for dynamic product routing in a manufacturing plant.





Symbiotic Simulation with Data Management

The aim of this project was to improve the speed at which simulation results of an automotive manufacturing line can be delivered by significantly reducing time to build the models and interpret the results. A discrete event simulation is a model that replicates the real world into an ordered sequence of events in digital form.


Water Accelerated Technology for En-Tyre Recycling

The WATER project focused on the development of an innovative tyre recycling process which enabled the optimal recovery of high value resources from end of life car tyres. The project concentrated on the development of a novel recycling technology which used Ultra High-Pressure Water (UHPW) to break down and separate materials from a tyre into three distinct resources.

Hybrid Fusion Energy System

The Hybrid Fusion Energy System (HyFes) project was an initiative to fit marine vessels with batteries and allow them to operate along the River Thames in a similar way a hybrid car would. The MBNA Thames Clipper river boat service and their high-speed catamarans were chosen as a test bed, due to its stop start capabilities in operation that would suit itself to hybrid propulsion.



The 'Manufacturing Gamification’ project proved that through the adoption of appropriate gamification techniques, employee engagement and productivity improved without compromising assembly quality. The project was a first for the implementation of the connection between gaming methods and the automotive industry.

Process visualisations

Combining digital tools and immersive technology to visualise, validate and optimise processes.

Layout Development

The planning of a facility layout including factory assets, building architecture services and utilities.

3D Visualisation

Using CAD tools to visualise products, processes and layouts.

Digital Twin Design

Using digital tools to develop and plan manufacturing production facilities.


Using digital tools to carry out work station readiness assessments.


Utilising digital tools to carry out capacity planning, material flow and process simulation.

Design for Manufacture

Instilling DfM principles in design and manufacturing processes, conducting Process Failure Mode &Effect Analysis (PFMEA) and Poka Yoke assessment.

Additive Manufacturing

Toolless layered manufacturing of complex components to optimise cost efficiencies.

Design for End of Life

Designing products with reuse and recover in mind, remanufacturing and designing for disassembly.

Design for Remanufacture

The method to design a sustainable product that is suitable for deconstruction and remanufacture.

Supply Chain Design

Mapping the value chain process of stakeholders to balance inventory, transport and manufacturing.

Virtual Tear Down

Using digital tools to provide manufacturers with future product manufacture and design visibility.

Digital BoP

Supporting business in the development of advanced digital capability in product and process manufacturing.

Electric Motor Manufacture

Supporting the future manufacturing capabilities in advanced technology needs, utilising in-house expertise.

Battery Manufacture

Consultancy on process development and optimisation within current and future battery technologies.

Fuel Cell Manufacture

Providing expert capability in high volume manufacture of next generation powertrain and energy technologies.