Log in
Novel statistical methods were developed in order to address the needs of Federal-Mogul Corporation (FM), an innovative and diversified $6.9bn global component supplier to vehicle manufacturers, with a broad range of customers in the industrial sector. During 2012, the research underpinned the production of new disc brake pad products for Audi, BMW, Ford, GM, Mercedes Benz and VW. The research has already resulted in significant benefits for the company by improving the manufacturing process, allowing it to be optimised to a mean specification, and by reducing the production cycle time by 30%.
Research into new process modelling tools and numerical simulation and optimisation algorithms at Imperial's Centre for Process Systems Engineering (CPSE) has resulted in a powerful new modelling technology. In 1997, a team from (CPSE) established a spin-out company, Process Systems Enterprise Ltd (PSE, www.psenterprise.com), to commercialise this process and energy systems modelling platform — gPROMSTM and to provide associated leading-edge model based services such as the design of new processes and the optimisation of existing processes.
Based on turnover (£400k at launch to £10m today), PSE is now recognised as a leading provider of process modelling technology and modelling platforms, with over 100 employees in high-end jobs. Its customers include most of the world's leading chemical, energy and automotive companies (e.g. Dow Chemical, BASF, BP, Shell, ExxonMobil, Toyota, Honda, Ford, Mitsubishi Chemicals) and it has a strong international presence with offices in the UK, US, Germany, Japan and Korea and agencies in China, India, Saudi Arabia and Thailand. The overall benefit to industry over the REF period is estimated to be £400m. The software allows customers to model, understand and optimise their processes in an unprecedented manner, leading to improved designs and more efficient operations. The gPROMSTM software is used in over 200 universities for both teaching and research (primarily the latter), where it enables research into new chemical and energy processes to take place.
The impact relates to improved productivity, operational efficiency, working practice and knowledge management within the European maritime industry through the use of a Virtual Integration Platform (VIP). The platform is a software package developed within the University of Strathclyde that has been used by eleven European ship design, engineering and project management consultancies, which specialise in the application of advanced computational design, analysis and physical modelling techniques within projects on an international scale. Specific company benefits of using the VIP include: 67% reduction in process time; guaranteed data consistency; additional productivity of 15 hours/day from automated over-night operation; capturing and reuse of expertise; cost effectiveness (lack of data consistency typically costs €100k per project); and ease of operation within complex design processes.
UCL research has been instrumental in creating critically needed new biocatalysts and bioprocess technologies for industrial biocatalytic process development. These have impact across the UK chemical and pharmaceutical sectors. BiCE enzyme technologies have been exploited through the formation of a spin-out company, Synthace, generating investment of £1.8m and creation of 7 new jobs. Commercial utilisation of BiCE enzymes by company partners has led to environmental benefits through sustainable syntheses and reduced waste generation. BiCE high-throughput bioprocess technologies have also been adopted to speed biocatalytic process development. UCL established a parallel miniature stirred bioreactor system as a new product line for HEL Ltd. [text removed for publication]. Related knowledge transfer activities have also benefited some 157 industrial employees from over 50 companies since 2008.
This case study describes the impact of the EnCore microprocessor, and the associated ArcSim simulation software, created in 2009 by the Processor Automated Synthesis by iTerative Analysis (PASTA) research group under Professor Nigel Topham at the University of Edinburgh. Licensing to Synopsys Inc. in 2012 brought the EnCore and ArcSim technologies to the market. Synopsys Inc. is a world-leading Silicon Valley company. It is the largest Electronic Design Automation (EDA) company in the world, and the second largest supplier of semiconductor IP. EnCore is achieving a global impact through this worldwide channel. The commercial derivatives of the EnCore technology provide manufacturers of consumer electronics devices with an innovative low-power, high-performance microprocessor that they can customize to their specific application requirements, enabling the next generation of electronic devices.
Research at the University of Manchester, focusing on process systems in advanced architecture for large systems, has enabled the development and successful implementation of the Salford Process Reengineering Involving New Technology (SPRINT) method within Salford City Council. SPRINT is a change and innovation method tailored to the needs of the public sector. Having been adopted as the standard for all Local Authorities in 2004, the SPRINT methodology aided Salford City Council in achieving savings of £20M by 2011. It has been further used in projects in Education and Housing where it has delivered cost savings of £0.5M.
Packaging is vital for sales and for product protection for all process industries, with the most widely used world-wide being board and film. For example, the grocery sector alone represents about 70% of the UK packaging market, with 10 million tonnes of packaging used each year.
Packaging materials are variable, which poses significant challenges in packaging machine design. A further challenge has arisen due to environmental legislation that requires the use of thinner, lighter weight materials. There is a need to meet these challenges since the size of the world market for packaging machinery is around €20bn, of which 2% is associated with the UK. Research at Bath has helped address these challenges in a number of inter-related areas:
Research has been undertaken in collaboration with industrial companies consisting mainly of SMEs, end users and research associations. Impact has been gained by embedding the results within the collaborating companies and by on-going use of the results by research associations.
Publically and industrially funded research at Loughborough University into the simulation, monitoring and control of electronics soldering has had significant impact in the development of new software and hardware technologies, which have delivered substantial commercial and economic benefits, with examples cited for at least two leading companies. One key commercial product is a modelling tool that optimizes reflow oven settings quickly, easily and accurately. It optimises oven settings each time a new product or solder paste is introduced, reducing set up times and scrap levels. More than 700 systems per year continue to be sold, with 90% exported.
Research conducted at the University of Cambridge under an EPSRC grant between 1999 and 2002 established the viability of using microwave induced pyrolysis as a process for recovering clean, elemental aluminium and hydrocarbon liquids and gases from waste laminate packaging, thus preventing the need to send this material to landfill. The research has been commercialised by Enval Limited — a multi-award-winning University spin-off founded in 2006 that has attracted approximately £2M funding during the REF period and employs 7 people. A pilot scale unit has been operational since 2011, and the first commercial-scale unit has been constructed and has operated since April 2013.
RTT (Real Time Tomography) scanning systems for airport baggage are becoming increasingly important due to growing air traffic and greater security concerns. Prior to our research, Rapiscan, a leading producer of baggage scanners, had been unable to make full use of the hardware in their latest generation of scanner prototypes. Our novel theory and image reconstruction algorithms are now a core part of a commercially successful 3D scanner that is significantly faster and more accurate than previous generations. The two models, RTT80 and large RTT110, have been approved by regulatory authorities and have already been field trialled at Manchester Airport and deployed at Seattle airport, with further US$20m orders placed.
The research and impact described herein was flagged in the citation for the UoM's 2013 Queen's Anniversary Prize for Higher and Further Education for its work in imaging techniques to support advanced materials and manufacturing.