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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.
Fluid modelling approaches devised by the Materials and Engineering Research Institute's (MERI's) materials and fluid flow modelling group have impacted on industrial partners, research professionals and outreach recipients. This case study focuses on economic impacts arising from improved understanding which this modelling work has given of commercial products and processes. These include: metal particulate decontamination methods developed by the UK small company Fluid Maintenance Solutions; liquid crystal devices (LCDs) manufactured by the UK SME ZBD Displays; and an ink-droplet dispenser module originally invented at the multinational Kodak. Additionally, the modelling group's computer simulation algorithms have been adopted by industrial research professionals and made available via STFC Daresbury's internationally distributed software package DL_MESO. Finally, the group has developed, presented and disseminated simulation-based materials and visualisations at major public understanding of science (PUS) events.
The research has enabled industrial simulation users to investigate and develop larger scale systems faster and cheaper and thus to explore a wider variety of cost-saving options with more precision, and industrial simulation providers to offer new high-performance simulation (HPS) products and services. As a direct result of this work: Ford has made £150,000 cost savings in consultancy and significant process improvements to engine manufacture globally; Saker Solutions (UK SME) has created the first ever HPS system for production and logistics; Sellafield PLC has used this system to make significant process improvements and savings in the management of nuclear waste reprocessing of around £200,000 per year; and Whole Systems Partnership (a UK SME) used a spin-off from this research to generate a £200,000 per year revenue stream from interoperable healthcare decision support systems. Globally, several other companies are adopting the standardisation efforts and other outcomes of the research as the foundation for future innovation.
The development of unique computer simulation tools has profoundly influenced the design and manufacture of silicon chips fuelling the $300 billion per year semiconductor industry. A pioneer of statistical variability research, Professor Asen Asenov developed understanding and awareness of statistical variability in the nanoscale transistors which make up all silicon chips. Gold Standard Simulations (GSS) was created in 2010 and by 2012-13 had grown revenue from services and licensing to $1million. GSS tools are currently used in foundries providing 75% of all semiconductor production for fabless design companies globally. For example, working with GSS and their simulation tools has reduced the development time for IBM's next generation of CMOS technology by 1 year, representing significant savings in the 3-5 year technology development cycle.
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 Computational Mechanics and Reliability Group at the University of Greenwich has been developing computational methods for predicting material behaviour and component reliability since the late 1990s. This case study details economic and environmental impacts and impacts on practitioners. In particular it shows how our expertise has:
Researchers in QUB developed the first commercial process control system (Rotolog) and simulation software (RotoSim) for the Rotomoulding Plastics Industry. There has also been recent commercialisation of a new energy-saving system, the Rotocooler.
The fundamental understanding of the process that was developed also enabled the moulding of new materials for new application areas, notably motorcycle fuel tanks (now used by BMW, Ducati, Harley Davidson and Honda) and the world's first concept car made from sustainable polymers.
Global economic and environmental impact arises from a significantly more efficient process, better product quality, a greater selection of processable materials and thus increased sales.
Loughborough University's (LU) interdisciplinary model based systems engineering (MBSE) research (2001-2010) has directly enabled life-saving operations by i) Developing synthetic vision systems to improve the safety of emergency services helicopter operations involving low level flight during day, night, all weather and conditions of zero visibility, and ii) Saving lives through a reduction in morbidity and mortality of babies born with congenital heart defects.
The impact translates directly into significant cost savings and safety risk reductions in expensive flight trials costing millions of pounds by BAE Systems [5.1], and in supporting clinical practice/surgical interventions by University Hospital of Rennes [5.2] with a reduction in the morbidity and mortality of babies born with congenital heart defects in Brittany, France.
This case study describes the creation and use of advanced simulation technology by international mining corporations to optimise high value metal recovery. The technology involved the development of advanced novel computational methods and software tools to model industrial scale heap leach processes for large scale industrial application at major mining operations. This focus on the development of optimised operational strategies has produced considerable economic benefits measured in the $multi-millions to industrial sponsors, including $58 million dollars in additional revenue for one multi-national corporation over one year following the adoption of engineered heaps based upon the advanced simulation tools from Swansea.
Research conducted at Warwick Business School (WBS), in collaboration with Warwick Medical School and Warwick Manufacturing Group, has provided new models and techniques for understanding and improving hospital processes and has been adopted by four NHS Trusts in England, informing their services and professional practice as well as enabling more efficient decision making. Research findings have been used to develop the SimLean concept, a simulation approach for use in hospitals. SimLean was developed in order to educate healthcare staff about lean principles and has been adopted commercially by the global company Simul8 as a platform for further development. Significantly, this research has also informed the national strategy for service improvement in the NHS.