The Advanced Materials Show 2019 presentation

1. Factory of the Future
The journey begins analogue to digital
Monitor Coatings Ltd
Dr Bryan Allcock FIMMM

2. Simple Quality Management System Relationship Model based on ISO9001 / AS9100
Customer
5.2
Sales
7.2.1, 7.2.2
Product Realisation &
Planning
7.1.1, 7.3
Order Entry
Purchasing
7.4, 7.4.1, 7.4.2,
7.4.3
Supplier
Production
7.5.1, 7.5.2, 7.5.3,
7.5.4
Receiving
7.4.3
Quality Assurance
7.6, 8.2.3, 8.3, 8.4
Testing
8.2.4
Shipping
7.5.5
Management
5, 5.1, 5.5.2, 5.6, 6. 6.1, 6.3, 6.4
QualityPolicy&Objectives
5.3,5.4.1
Communications
5.5.3
Resources&Training
6.0
ContinualImprovement
8.5.1,8.5.2,8.3
InternalAudits
8.2.2
RELEASED PRODUCT
Product Test Reports
SHIPPED PRODUCT
PRODUCT
Response to Field Non-Conformities
Process Control Information & Requirements
Management Review
5.6.1
Quality Assurance Input
Material Cert. & Reports
Purchased Material
Purchasing
Information
7.4.2
Material Specification
ACCEPTED
MATERIALS
Manufacturing Input
Customer Requirements
Customer Feedback & Needs
8.2.1, 8.4
Order Communication, Feedback & Complaints
7.2.3
Production
7.5.1, 7.5.2, 7.5.3,
7.5.4
Industrial IoT Network Centric
Industrial
Apps
Quality
Monitoring
Tools
Sensors
Safety
Automation
INDUSTRY
4.0
Property of TRL9 Limited

3. Historic Standard Process Flow for Nozzle Guide Vanes - Production
Booth Validation
Issue Job card & Job
to Shop Floor
Product Realisation
& Planning
7.1.1, 7.3
Receiving
7.4.3
Inspection Degrease Mask for grit blast Grit Blast
De-MaskInspectMask for Coat
Jig with Inspection
Blanks
Re-work
R
R
Planned
Preventative
Maintenance
Set Parameters
Weigh Powder
Tab Sample Coated
Laboratory:
Hardness
Structure
Porosity
Unmelts
Oxides
Roughness
Adhesion
Grit Inclusion
Inspect Apply Bond Coat Inspect
Apply Top CoatInspectDe-jig
De-mask Inspect Clean-up
Re-Mask / Tooling InspectSuper FinishedDe-maskinspect
Final Inspection
Dispatch to
customer C of C
R
R
R
R
R
Thermal Monitoring
Property of TRL9 Limited

4. Initial IIoT Approach Process Flow for Nozzle Guide Vanes - Production
Booth Validation
Issue Job card & Job
to Shop Floor
Product Realisation
& Planning
7.1.1, 7.3
Receiving
7.4.3
Inspection Degrease Mask for grit blast Grit Blast
De-MaskInspectMask for Coat
Jig with Inspection
Blanks
Re-work
R
R
Planned
Preventative
Maintenance
Set Parameters
Weigh Powder
Tab Sample Coated
Laboratory:
Hardness
Structure
Porosity
Unmelts
Oxides
Roughness
Adhesion
Grit Inclusion
Inspect Apply Bond Coat Inspect
Apply Top CoatInspectDe-jig
De-mask Inspect Clean-up
Re-Mask / Tooling InspectSuper FinishingDe-maskinspect
Final Inspection
Dispatch to
customer C of C
R
R
R
R
R
Thermal Monitoring
Operations Inspection Mask / Jig Validation
Issue Job card 0.42
Incoming Inspection 2.17
Degrease 0.33
Mask For Grit Blast 5.00
Grit Blast 3.00
De-Mask 1.00
Inspection 0.17
Mask for Coat 5.00
Jigging 2.00
Booth Validation 2.75
Inspection 0.17
Apply Bond Coat 0.50
Inspection 0.17
Apply Top Coat 4.00
Inspection 0.17
De-Jigging 0.17
De-Mask 2.00
Inspection 0.17
Clean-Up 4.00
Inspection 0.17
Re-Mask for Super finish 1.00
Super finish 2.00
De-Mask 2.00
Inspection 0.17
Final Inspection 3.00
Dispatch 0.50
Total (Man Hours) 13.75 3.17 22.33 2.75 42.00
Property of TRL9 Limited

5. Consolidated Process
Requires integration
with Customer Interface
3D printed masking from
individual part CG Data
supplied by customer
Continuous monitoring
using thermal, optical
imaging & acoustic
emission. Virtual
Powder control
Universal jig design
tagged to part for
traceability
Degrease
Apply Bond CoatApply Top CoatSuper FinishingFinal Inspection
Dispatch to
customer C of C
Grit Blast
• Migration to cluster projects
linked to IIoT policy.
• 27 discrete operations
reduced to 9 operations
• Server reliability and
connectivity
– MQTT Protocol
– MQTT Library for Big Data
– MQTT Broker over network
• IIoT Platform
– Ease of intergration on front end
application
– Cost to buy or subscribe
– Pre-curser platform software, not
plug and play
• Stress Tested Artificial
Intelligence and Machine
Learning Algorithms
Property of TRL9 Limited

6. Key Findings & Questions
Powder Control Initiative
• 27 discrete operations and Booth
Validation Process.
• 14 accompanying documents and
samples: PO / PTS / Traveller / Grit Blast
Record / Size Sheet x 4 (thickness
measurements) / Certificate of
Conformance / Data Card / 4 x samples
for cut up.
Infra Red Thermal Imaging
• Raspberry Pi £35.00
• IR camera / thermometer £220.00
• HDMI Screen £105.00
• Raspberry Pi £35.00
• HDMI Screen £105.00
• NodeRed + PHPmyadmin software FREE
• Digital scales (USB)
• Where do we make decisions?
• Criticality of decisions varies
• Need to desensitize process to account
for aging workforce and high dependency
on tacit knowledge
Property of TRL9 Limited

7. Comparison of Aerospace versus Steel
Aerospace Steel
• Billet Mould• Nozzle Guide Vane
Operations
65%
Inspection
13%
Mask / Jig
10%
Validation
12%
Operations
33%
Inspection
7%
Mask / Jig
53%
Validation
7%
• Decision points: 27 opportunities to mess things up
• AS9100 / NADCAP
• Decision points: 13 opportunities to mess things up
• ISO9001
Property of TRL9 Limited

8. IIoT Project Board Achievements
Each project and
Project Element
measured
COMMAND
CENTER
Increased
Productivity
Return on
Investments
Digital Input
Masking
Jigs & Fixtures
Booth Validation
Man-Power
Conformance
On-Time or Better
Waste
Re-Usability
Down-Time

9. Monitor Coatings Ltd Business Transformation Map – Reviewed Continuously
2023202120202019 2022
£AM. HVM
requirements
identified &
exploitation begun
Expansion &
Reduction of current
technology
landscape portfolio
NANOCAST / CAUTION & Coating
simulator algorithm
Automation for New Opportunities -
reshuffle XXX / XXX
Aerospace & Nuclear
partnerships
Automation for New
Opportunities - Investment
Rotating torch cHVOF
cHVOF development.
Flexibility in proses
standardization. 1 gun fits
all approach
£AM. Review global
reach
Portal Based Sales
Research & Development Manufacturing Capability Levels Partnerships & Co-operations
ProcessesSales
£AM. Widen the net in
Journey Board, Blue Sky
opportunities expansion
Make or buy approach
to expand offerings
Materials & Sensors for
inputs not outputs
Automation &
integration of sensors –
factory of the future
Automotive – battery
technology
MCL 2024
MCL 2018
expand to Italy, USA,
Australia & Japan
Digital Manufacturing Buy-
in for new skill sets
Automation
Process capability tailored
to strategic partner
requirements
£AM. Sales driven by
strategic partnerships
Risks & Dependencies
• Think Global Act Global strategy
• Major global events (elections, recessions, BREXIT etc.)
• Incorporate future forecast data directly into the control horizon
• Changes in economic, social, environmental and technology landscape
• Ability to meet MCRL requirements
• Roll-out of technologies & benefits of a global sales team?
Property of TRL9 Limited

10. Thank You