Completed Materials & Manufacturing Education & Skills

Made Smarter Innovation - People-Led Digitalisation

In plain English

AI plain-English summary

A 47% productivity boost in aerospace manufacturing came not from better software, but from a step-by-step process that combined data analytics with close observation of how people actually work. The problem is that UK manufacturers have spent decades buying digital tools—automation in the 1980s, smart sensors today—without seeing the promised productivity gains. The Made Smarter Review (2017) found that the bottleneck is not technology but people: employee pushback, missing skills, poor change management. Each sector claims its challenges are unique, but the underlying human factors are common. This centre aims to create a generic, sector-agnostic process that any manufacturer—from a 56% share of SMEs to nuclear facilities—can follow to get employees genuinely engaged with digitalisation. If the process works across UK manufacturing, the impact would be steady, year-on-year productivity improvements without requiring new hardware. Supply chains become more responsive, production lines more flexible, and the workforce more capable of making smart decisions from live data. The research is applied and industry-facing, building directly on a proven aerospace case study.

View original technical description
Imagine you are responsible for the digitisation journey of your company's manufacturing. You know by embedding digitisation throughout the whole manufacturing value chain will bring success. However, your manufacturing portfolio is diverse e.g. high volume fast moving white goods, novel pharmaceutical biological drugs, automotive components, chemical synthesis and aircraft avionics. You also design, manufacture and operate nuclear facilities. Each of the sectors claim they are unique; however, your experience evidences the underlying challenges are common - although often articulated in different ways! You have learnt lessons from the 1980's where companies adopted automation because 'it was the new shiny technology" but productivity savings were not always realised, and the Made Smarter Review evidenced that in 2017 productivity challenges, still remain - even though the technology is available. You know that people are the critical element. You have seen manufacturing systems fail to deliver because of employee pushback, lack of engagement/skills/leadership as well as poor change management (Made Smarter Review 2017, Vander Luis Da Silva, et al. 2020). You recognise to create value in manufacturing through digitalisation needs investment in people. It is your view that the right combination of current technology, data and people can deliver SMART manufacturing today i.e. if we have the right people, we can be responsive, reactive, make smart decisions to maximise manufacturing value using live data and information. However, to achieve digitally engaged people, especially in manufacturing you believe there needs to be a process for manufacturing companies to follow, regardless of sector and size. The vision of this centre is to enable 'UK Manufacturing to improve their productivity year on year by investing in their biggest assets - people"". This investment will lead to the uptake of digitalisation. As part of our ambitious centre, Theme 4 - "Societal and cultural change: managing the disruptive impact of digital technologies." i.e. achieving digitally engaged people is core and will account for up-to 65% of our activities. Around 56% of UK manufacturing (Q2, 2019) are SMEs which are critical to UK Manufacturing. To meet our goal of digitally engaged people our research will engage the whole manufacturing value chain through Theme 3 - "connected and versatile supply chain" our second core theme However, we recognise investing in people will 'touch' all of the themes and our networking activities will be crucial in leveraging value from the Made Smarter investments. In summary, our hypothesis is that regardless of manufacturing sector and company size a common process leading to digitally engaged people is achievable in practice i.e. in industry. Impacts from embedding our research into aerospace manufacturing demonstrated the data/information engineers believed they needed, was not the data/information they used to make decisions. We were able to increase their productivity by 47% through a combination of manufacturing digitalisation and human factors. This was achieved through a step-by-step process, using data analytics, human factors and observing people in action. Our centre will build on this expertise and create a generic process for use across UK manufacturing - leading to increased productivity.

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Researchers

Alborz Chaharsooghi (Co-Investigator)Andreas Kyprianou (Co-Investigator)Brett Edwards (Co-Investigator)Charles Larkin (Co-Investigator)Chris Brace (Co-Investigator)Ella-Mae Hubbard (Co-Investigator)Evripides Loukaides (Co-Investigator)Felicia Fai (Co-Investigator)Joseph Flynn (Co-Investigator)Layla Branicki (Co-Investigator)Linda Newnes (Principal Investigator)Marcelle McManus (Co-Investigator)Maria Battarra (Co-Investigator)Mariachiara Barzotto (Co-Investigator)Mark Jeremy Brosnan (Co-Investigator)Matthew Davidson (Co-Investigator)Nic Zhang (Co-Investigator)Nicholas Pearce (Co-Investigator)Paul Shepherd (Co-Investigator)Philip Robert Tomlinson (Co-Investigator)Rebecca Grant (Co-Investigator)Richard Burke (Co-Investigator)Robert Houghton (Co-Investigator)Samuel Cooper (Co-Investigator)Sarah Sharples (Co-Investigator)Ulrich Hintermair (Co-Investigator)Vaggelis Giannikas (Co-Investigator)Vimal Dhokia (Co-Investigator)Yee Mey Goh (Co-Investigator)

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Original classification

Research Grant

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