Challenging automation thinking and planning
CARL ZEISS MICROSCOPY
Carl Zeiss Microscopy is a technology manufacturing company based near Cambridge and part of the international ZEISS Group. The Cambridge manufacturing facility has responsibility for production of ZEISS electron microscopes, which are used in a wide variety of applications in scientific research, and industrial research and quality control.
Daniel Aldridge, Managing Director for Carl Zeiss Microscopy, tells us about why the IfM Engage approach worked for them.
What industry challenges were you facing?
Digitalisation and connectivity are mega-trends in manufacturing, for which ZEISS itself provides many solutions from its portfolio of products and technologies. With so many possible options, technologies and buzzwords around Industry 4.0 and digital factories, we wanted to avoid the trap of adopting technology for its own sake, or chasing pet projects, and so we approached IfM Engage to bring external perspectives and academic rigour to our thinking and planning.
A good example of this is Auto-ID technologies (such as barcode or RFID) upon which several of our planned automation projects depended. We wanted to better understand how to deploy this along the manufacturing process steps and which technology to use at which points to maximise value creation.
How did IfM Engage support your work?
We have worked closely with IfM Engage for many years, for example in developing strategic and technology roadmaps, process improvements and more recently support in developing a roadmap for our manufacturing automation projects.
We had confidence that they understood our business and crucially would be able to work effectively with us using a robust and methodical process to develop practical, real-world solutions to the challenges we were facing.
In early 2020, we began an Automation Assessment with IfM Engage, starting with a detailed walkthrough of the end-to-end production process and then a series of workshops with a broad spectrum of team members to identify automation opportunities and projects. Although the COVID-19 pandemic forced us to change some of our plans, in the main we were able to keep to the timetable of the Assessment, which successfully concluded with ranked and prioritised automation projects.
Of these projects, we identified a cluster of projects that depended on Auto-ID technology. This cluster of projects was a good fit for an IfM student project giving us an external perspective and expertise on the different options. We currently have an ISMM student working with us to shape the approach we will take in deploying directly into the factory.
IfM Engage has shown great enthusiasm in working with us locally but also in engaging with the wider ZEISS network, such as the corporate logistics and corporate IT teams, to obtain a broad understanding of the ‘bigger picture’ like the underlying architectures defined in the ZEISS Connected Smart Factory.
What stands out about the IfM Engage approach?
Several things stand out about the approach. Firstly, although founded on world-class academic research, IfM Engage has its feet firmly on the ground with a practical approach honed over many years of working with industry.
Secondly, the intensity of working is at a high level, with a strong focus on tangible outcomes.
Thirdly, the follow-up is excellent and there is a genuine desire to support the company in achieving progress to the next level.
What has been the impact of working with IfM Engage?
Since completing the Automation Assessment, we have been able to clearly prioritise projects with the most value and put a strong focus on those. This has had a big impact with projects already successfully implemented, like digitalisation of major processes, and projects in development, like utilising the lights-out (overnight) period more effectively.
We plan to continue working closely with IfM Engage to develop our capabilities and improve our productivity, taking us ever nearer toward our vision of a world-class, digital lean factory.
“Although founded on world-class academic research, IfM Engage has its feet firmly on the ground with a practical approach honed over many years of working with industry.”
Daniel Aldridge, Managing Director, Carl Zeiss Microscopy
“Although founded on world-class academic research, IfM Engage has its feet firmly on the ground with a practical approach honed over many years of working with industry.”
Daniel Aldridge, Managing Director, Carl Zeiss Microscopy
About Carl Zeiss Microscopy
Carl Zeiss Microscopy, part of the international ZEISS Group, produces ZEISS electron microscopes, which are used in a wide variety of applications in scientific research, and industrial research and quality control. Their award-winning manufacturing processes are based on lean principles and continuous improvement, enabling efficient service to a global market.