Virtual reality deployed to optimise production processes
Virtual reality and simulation technology has been deployed in a novel way to help design the physical layout of a new nickel plating facility in Chesterfield and optimise complex production processes at the site.
NiTEC UK – a division of CBE+ – embraced the technology to aid the design of its Electroless Nickel Plating facility with digital support from engineers at the University of Sheffield Advanced Manufacturing Research Centre (AMRC).
Electroless nickel plating is a chemical process that deposits an even layer of nickel-phosphorus alloy on the surface of a solid substrate. The process is typically used to improve corrosion protection, hardness or wear resistance for an array of applications, from subsea to space and medical to defence.
Insights gained from the use of virtual reality simulation informed a decision by the company to invest in robotics systems.
AMRC project manager Dr Phil Yates said: “The markets and the complexity of what they make has grown enormously at NiTec. They now manufacture products for several different sectors from performance automotive to the military.
“To optimise their complex range of processes, we first mapped out the various products into families, grouping these together to explore options for the layout, as well as the chemistry of their production. We analysed a range of data and used a virtual reality simulation to come up with the optimal solution.”
He added: “This wasn’t just about their shop floor, this project looked at rationalising every element of their manufacturing processes.”
CBE+ group technical director Chris Brown said: “The AMRC supported us to create and navigate around a new space using virtual reality. It’s a useful way to do it – as you can imagine, if you had to start pouring concrete in the ground and building the new layout in order to test it, the whole thing would be cost prohibitive.”
He added: “This work has ended up going in a new direction after a pause due to Covid-19, and we’re now looking at bringing in robotics to achieve the outcomes we want to see. Our work with the AMRC helped us identify the best way forward for our business, in a relatively cost-effective way.”
Mr Brown suggested that the use of virtual reality technology to explore possibilities in a cost effective manner could offer similarly significant benefits if applied to maintenance processes.
The project was paid for using funds from the High Value Manufacturing (HVM) Catapult as part of a commitment to working with small and medium-sized enterprises.
