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.
Electric Vehicle Powertrain School
Electric Vehicle Powertrain School (EVPS) is an advanced-level, technical boot camp designed to teach delegates how to design for manufacture, build and run production of the different primary elements of an electric vehicle’s (EV’s) powertrain. The EV industry is due to grow exponentially and it’s vital that those involved in automotive manufacturing, and its surrounding industries keep their technical knowledge up-to-date to remain at the forefront of the industry.
CoBot Design & Certification
The Cobot Design and Certification (CDC) service is a unique offering which assesses the feasibility of implementing truly collaborative applications in an industrial environment, by using virtual design and simulation. Establishing the suitability of collaborative applications before making significant investment ensures that the end solution is fit for purpose and meets current standards.
Circular Economy Readiness Review
The Circular Economy Readiness Review is a multi-level assessment for evaluating circularity of products, business models and environmental factors. The CERR service delivers an in depth assessment of businesses and provides a strategic roadmap for progression to the next level in circularity.
Digital Readiness Review
Digital Readiness Review is a comprehensive and strategic workshop, delivered by experienced HSSMI consultants, to assess your organisation’s current and desired digital future state. Through the expert advice and facilitation of our consultants, we will work closely with your organisation to understand your business goals and objectives, before developing a strategy to reach them.
Developing Interactive Virtual Reality Environments
Our team of skilled visualisation engineers have combined their shop floor knowledge with the latest advancements in the world of Virtual Reality (VR), creating computer-generated immersive simulations that can be explored and interacted with by people across all areas of the business using a Head Mounted Display (HMD).
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.
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.
Future Market Study for JW Froehlich UK Ltd
JW Froehlich UK Ltd have supported the automotive industry throughout their 40 years, producing leak tests, engine hot and cold tests and other machine technologies. JW Froehlich UK Ltd have constantly evolved their offering and are now looking to maximise the opportunity of being at the centre of change following automotive powertrain electrification.
Cobot Design and Certification (CDC) for Ford Motor Company
Ford Motor company, specifically their Dagenham facility, aims to introduce an automatic checking system using collaborative robots for quality checking of electrical harnesses. As a part of the Cobot Design and Certification (CDC) service, HSSMI provided a project, with a set of defined deliverables, to assess the suitability of collaborative robots for this application.
Virtual Reality Support for Ford Motor Company
Ford Motor Company announced that they were looking to introduce the use of Virtual Reality (VR) into the manufacturing side of their business, on a trial basis, in order to understand the benefits of adopting this technology into their wider organisation. HSSMI therefore provided a short-term project with a set of defined deliverables to enhance the experience of using VR.
Risk Assessment for Collaborative Environments
Risk Assessment for Collaborative Environments (RACE) is a feasibility study which envisioned the development of a simulation tool to perform virtual risk assessments of collaborative applications. Using inputs such as the robot’s program and/or task, the operator’s task and CAD models of the workstation and the production facility, a simulation is performed to identify any risk of collision between the robot and the operator.
Industrial Ergonomic and Assembly Analysis with Optimisation for CNH Industrial
CNH Industrial hoped to create a template for the enhanced, sustainable deployment of advanced lean techniques within a ‘New Assembly Line Standard’. Specific assistance was sought from HSSMI within Automation, Process Planning and Ergonomics such that these could be utilised as a standard for future CNH Industrial assembly line installations.
Occupancy Study for Loughborough University London
Loughborough University London (LUL), located on the Queen Elizabeth Olympic Park in East London, has experienced a surge in postgraduate students attending the campus to study. Due to the running cost of a workstation and the opportunity to maximise the utilisation of space, the university intends to use a system where they can monitor the behavioural patterns for the utilisation of the workstations and meeting rooms.
Material Flow Simulation for Ford Motor Company
Material Flow Simulation was a commercial project which established the current state of the material flow for the trim line at the Ford Valencia plant through the generation of a simulation model.
Virtual Reality for Factory Cell Comparison for AGM Batteries
Virtual Reality (VR) for Factory Cell Comparison is a project which envisioned the generation of a virtual reality environment to facilitate the comparison of a newly designed battery cell, incorporating RF technology against a traditional battery cell design.
SME Productivity Improvement for Instant Spaces
Instant Spaces is looking to mass produce structural and insulated building panels, upscaling the batch operation they currently perform at their London site. HSSMI developed a project with a defined scope of works and deliverables, to support Instant Spaces with their long-term vision of mass production. HSSMI delivered an on-site process mapping exercise detailing the current state followed by the development of a future state process map.
Augmented Manufacturing Reality
The Augmented Manufacturing Reality project (AMReality) involved the creation of an integrated virtual and physical manufacturing environment overlaid with digital data (e.g. CAD, simulations, video etc.) alongside information about the physical environment (e.g. size, temperature, power usage etc.)
Combining digital tools and immersive technology to visualise, validate and optimise processes.
The planning of a facility layout including factory assets, building architecture services and utilities.
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.
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.
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.
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.