The Advanced Materials Show 2019 presentation

1. Digital Manufacturing in Coatings:
Lessons from other High-Value
Industries.
Allan Matthews, University of Manchester
Director BP-ICAM
Track 2: Advanced Coatings &
Surface Engineering.

2. • Early studies and background.
• The Special Interest Group study into Surface Engineering and Advanced
Coatings (SEAC).
• Surface Engineering Leadership Forum (SELF).
• The EPSRC NetworkPlus in Digitalised Surface Manufacturing (DSM+).
Content of the presentation

3. 3 Early Reports
• 1992
– "The UK Engineering Coatings Industry in 2005“.
– ISBN 0859587436
• 1998
– “2005 Revisited: The UK Engineering Coatings Industry to 2010”
– ISBN 095328 – 7203
• 2010
– “The UK Surface Engineering Industry 2010”
– ISBN 978-0-9567041-0-8
These early reports highlighted that practices in the UK coatings
industry didn’t meet the standards found in other High Value
Manufacturing sectors

4. Examples of deficiences
highlighted included:
• A lack of integration with Product Design.
• Lack of defined and rigorous Standards.
• Lack of “Intelligence” - about market developments,
technical choices, coating properties and process
variability (as examples). (Generally, a lack of
conformance with characteristics expected of High
Value Manufacturing processes).

5. Government agencies tried various approaches
to remedying the problems, including the
establishment of a National Surface Engineering
Centre (NASURF), as well as direct funding
support schemes, but many of the deficiencies
still remained UNTIL NOW!
In 2014 a Special Interest Group established by
the KTN to examine the Surface Engineering and
Advanced Coatings (SEAC) sector produced a
Report which has achieved buy-in from across
the sector (Industry and Academia) and this is
leading to major changes.

7. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
The report can be downloaded by following
the link below.
https://connect.innovateuk.org/web/material
sktn/article-view/-/blogs/surface-
engineering-and-advanced-coatings-
report?p_p_auth=M1BcARIz

8. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
The report was the result of many Advisory Group
Meetings as wall as many Working Group
discussions as well as consultation meetings with
the wider SEAC community.

9. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Why a SIG in this area?
• Surface Engineering and Advanced Coating
technologies have been identified as one of the 22
national competencies in TSB’s HVM Strategy
• Previous reviews by the Industry showed significant
market opportunities in key application sectors
• TSB set up the SIG to identify the technology and
innovation needs of the industry and to recommend
specific areas where TSB investment will help UK
manufacturing

10. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Overview of SEAC SIG and its Findings
The SEAC SIG study looked at:
• The SEAC market
• Drivers for using SEAC technologies innovation
• Actions to address barriers to innovation
• Supply chain characteristics
• Analysis of a strategy workshop

11. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Excluded – Electronics manufacturing
Surface functionlised consumer goods- e.g. washing powders, cosmetics.
Wide Range of Processes

12. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Market Advantage
The UK Surface Coating and Treatment
Market
The most recent study is: R J Artley and A Matthews, “The UK Surface
Engineering Industry 2010”. Report Sponsor: Surface Engineering Association,
2010, ISBN 978-0-9567041-0-8.
Keith Harrison and Allan Matthews updated the figures to include
sector definitions now used by TSB and Government to include
sectors such as Food and Drink, not listed in the above report.
The value of industrial sectors that are important users of
coatings is over £383billion (up by more than £130billion on
previous estimates).
The value of products directly affected by coatings is over
£140billion.
The value of surface coatings and treatments applied to those
products stands at about £11billion.

13. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Application Sectors (£billions)
(cost of coatings used in each sector)

14. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Value Chain
R&D
Product and
Service
Development
Supplier
Management Production
Route to
Market
After Sales
Service
and
Use
Disposal

15. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Drivers – Common Themes
• Enhancement of product performance
− Step change improvement to products,
− Product differentiation and enhanced competitiveness,
− New market opportunities,
− Market qualifier,
− Advancing up the value chain,
• Cost effective products through efficient materials
utilisation
• Changes in the business environment, e.g REACH
• Improved sustainability
• Supply companies need SEAC technology applicable in
many different applications and readily transferable

16. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
A Strategic Workshop was held.
• Aimed to expand and test the conclusions of the study
• Make key recommendations for support to the industry
• 3 key questions were addressed:
– How do we maximise the value from innovation in SEAC
technology?
– How can the SEAC supply chain become a strategic element of
High Value Manufacturing?
– How do we change the game in manufacturing in the SEAC
supply chain and maintain competiveness through the product
life cycle?

17. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Barriers to Adoption of Technologies
Low confidence and uncertainty
• Uncertain long-term performance of coatings
• High financial risk (Poor cost benefit) in introducing SEAC
technology
• Complex and costly qualification processes for certain
markets. Often lack of industry standards.
• Wide ranging and fragmented supply chain leading to
poor flow of information; Uncertain who can provide
particular technologies and has facilities.
• Perception that the supply chain is inward looking and
conservative rather than proactive to industry needs
• Many processes are skills based

18. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Effecting a strategic change - SEAC should
become a fully digitalised HVM Technology
sector thriving in competitive global markets
– sector must develop its capabilities to provide the service
and confidence that customers are seeking
– action to develop the “manufacturing-innovation
ecosystem” within the SEAC community
Themes
• Improved Awareness
• Becoming a Strategic Process
• Better Design Approaches
• Accessing Facilities and Building Capabilities
• Increasing Proactivity

19. Knowledge Transfer Networks
Accelerating business innovation:
A Technology Strategy Board programme
Knowledge Transfer Networks
Accelerating business innovation:
A Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Standardise
MCRL / TRL
3
Develop &
Validate
Create
standards
Service
experience
Validated
standards
Process
Control
Utilise in
‘application’
supply chain
Identify technology
requirements
Process
definition
1
9Today:
Significant focus of
end-user resources
is supporting
current ‘application’
supply chain
Future:
Greater focus on
developing a DFM
culture with the
coatings supply
chain.
How do
we
change
the
game?
PullthroughCapability
Technology Pipeline – Product Lifecycle
Accelerated/
Robust
testing

20. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Acquire better performance characterisation
• Structure/property/performance data
• Accelerated tests are needed
• Life cycle simulation to predict in-service life
Support more applied and industrially relevant research
• More applied and industry-relevant research programmes in areas
of business opportunity
• Product innovation
• Understanding of the variability and sensitivity of SEAC processes
to make more robust
Actions Addressing Barriers

21. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Actions Addressing Barriers
Improve technology transfer
• Encouraging cross sector exploitation
• Increased awareness of and access to existing production-level
equipment and capabilities in companies and the research base.
• Provide pilot plant and demonstrator facilities
Address sustainability and environmental impact of coating
systems
• Sustainability of materials supply
• H&S and REACh eg hexavalent chrome and cadmium based coating
systems

22. These barriers will be addressed by Networking
both Industry and Academia.
The first Network to be created has been “SELF”
(Surface Engineering Leadership Forum).
The second is an EPSRC-funded NetworkPlus
“DSM+”
SELF and the DSM+ will work closely together.

23. Knowledge Transfer Networks
Accelerating business innovation;
a Technology Strategy Board programme
Surface Engineering and
Advanced Coatings
Recommendations
1. Establish a Leadership
Forum for surface
engineering and
advanced coatings

25. SEAC Industry Growth
Structured Transformational
Change Strategy:
Effect on Productivity & Profit
Continue With Current
Mode of Operation:
25

26. HOW TO WIN
WHERETOPLAY
TRANSFORMATIONAL
Phase 3. Design for
Manufacture
ADJACENT
Phase 2. Implement Digital
Manufacturing Culture
CORE
Phase 1. Operational
Improvements
Apply Design for
Manufacture
Plug the Digital
Gap
Apply 7 Wastes
Methodology
MatchFitBestinClassWorldClass
Transformational Change.

27. Help is at Hand SEAC Leadership Forum

28. Intuition (Just fix it)
Kaizen in Engineering
Lean
5’s etc
Focus: On
Outputs from
a Process.
Focus: On Inputs &
Outputs from a
Process.
Focus: On
Outputs from
a Process.
SPC
Scatter Plots
Capability Indices
DOE
Shainin
Taguchi
DFM
DFA
Robust Designs
Focus: On Optimised
designs made by
capable processes

29. Elements of process control
Asset care,
control of
inputs and
PFMEA
Process
basics and
control
Reaction
plans
Predictable performance Variation reduction Cost and quality
Engineering
standard ,
control
strategy and
validation
Engineering
attributes
Process
capability
and KPV
strategy
Process
FMEA

30. YEAR
WEEK
20132013201320122012201220122012201220122012
2012550433629221581
0.05
0.04
0.03
0.02
0.01
0.00
Proportion
_
P=0.00058
UCL=0.00136
LCL=0
Stage1 Stage2 Stage3
1
Sigma Z = 2.58427, 2.14332, 0.601041
Tests performed with unequal sample sizes
Pt Composition Reject Metric Chart
and Compliance
Care activities
on-going Asset
Current Checks,
Continuity &
Data as shipped to customer
XDV-SDD
with
90% Check
Verification
In Process
In process
verification
introduced
Asset
care, in
process
checks
and
complia
nce
audits
Improving the processes - Reduce
variability
Information courtesy of Turbine
Surface Technologies Limited

31. Examples of IoT Integration in HVOF Thermal Spray Coatings
11 July 2019 www.TRL9Ready.com 31
Process
Inputs
• Worn parts can be identified
through Spectral Density
(thermal and visual).
• Correlation of coating
properties with Acoustic
Emission signals
• Noise peaks can be identified
from process issues.
1
2
3
Nozzle
Exit
Flame
Body
Flame
Tip

32. • Encourage academic research in the Surface Engineering field, in support of
the SELF industry-led network
• Implement improved process and coatings modelling
• Facilitate state-of-the-art coating facilities.
• Drive improved digitisation in the coatings sector (processes and coating
properties).
• Implement improved characterisation and analysis.
• Improve performance evaluation and test methods.
• Accelerate fruition of new innovations to market.
• Enhance coating throughput rates.
• Facilitate full LCA for coated products.
• Above list is continuously developing
SOME WORDS ABOUT THE DSM+
NETWORKPLUS AND WHAT IT WILL STRIVE
TO DO…..

33. DSM+ will launch in September.
SELF is already running.
Bryan Allcock will now summarise steps
taken by one company to take coating
processes into a “digitalised” future.