Despite all the attention given to electrical schematics, interface configuration and motor logic, one question is often overlooked: what happens when something goes wrong?

Offshore environments are inherently high-risk. Platforms are isolated, weather conditions change fast, and emergency response options are limited. That is why offshore survival training has become a non-negotiable foundation for anyone expected to work in or support offshore operations. It is not only relevant for deck crews or marine personnel, but increasingly important for automation engineers, control technicians and system specialists who install, inspect and maintain offshore assets.

Why safety training must match technical skill

Modern offshore platforms rely on complex automation to run drilling operations, manage power systems, monitor sensors and ensure stability. The teams who service or install these systems often rotate in on short contracts, perform high-pressure tasks in confined spaces and interact with equipment that cannot be easily shut down.

Offshore survival training equips technical staff with more than general safety rules. It teaches how to stay calm in low-visibility conditions, escape from a smoke-filled compartment or survive a sudden evacuation. These are not distant, hypothetical scenarios; they are possibilities that must be planned for, especially when systems or environments don’t respond as expected.

Training typically includes helicopter underwater escape, use of life rafts, fire and smoke response, first aid and cold-water exposure. While these skills may seem unrelated to automation work, the reality is that an automation specialist might be the only one on-site who can initiate a safety override or direct others during a control system failure. Preparation in these situations can make the difference between minor disruption and serious incidents.

The BOSIET Certificate: A shared safety standard

For most offshore roles, holding a BOSIET certificate is the minimum requirement for deployment. BOSIET, which stands for Basic Offshore Safety Induction and Emergency Training, is an internationally recognised programme that focuses on real-world risks and how to respond to them in an offshore context.

It is often the first certification an engineer or technician receives before taking an offshore assignment. The programme covers core elements like personal survival techniques, fire safety, first aid and the use of emergency breathing systems. The goal is not to turn specialists into first responders, but to ensure that everyone working offshore can protect themselves and help stabilise a situation before dedicated rescue arrives.

The BOSIET certificate also serves as a common language across teams. When everyone has gone through the same drills and knows what the protocols are, coordination becomes faster and smoother. This is especially important for technical contractors or systems engineers who may be on-site for a few days or weeks but still need to integrate into ongoing safety procedures.

Where expertise meets emergency preparedness

In high-spec industries like automation and control systems, professionals are expected to keep operations stable and efficient. However, offshore, that expectation includes the ability to handle unpredictability; technical readiness and personal safety must go hand in hand. It is not enough to know how to wire a control cabinet if you cannot locate an escape route under pressure or recognise the signs of exposure in a coworker.
Companies and training providers that work with offshore industries understand this. That is why they continue to offer offshore survival programmes tailored to engineers, inspectors and installation teams. Providers like FMTC design their courses with practical, scenario-based instruction that reflects the risks automation professionals face.

Conclusion

Control systems and drive technologies form the backbone of offshore platforms, but they rely on human expertise to keep them running safely. For professionals in the field, investing in offshore survival training is not an added burden. It is part of being ready for everything the job demands, both technical and environmental. When backed by a recognised BOSIET certificate, that training ensures the people behind the systems are as prepared as the equipment they install.

Emerson’s Project Beyond will deliver the industry’s first software-defined, OT-ready digital platform that seamlessly integrates and optimises industrial operations. Leveraging innovations in software-defined control, data management, zero-trust cybersecurity and artificial intelligence (AI), Emerson’s new platform will help automation investments deliver value without adding complexity.

The speed of technology and industrial AI advancements, combined with increased computing power needs and the unprecedented volume and complexity of siloed data generated across industrial assets, requires a new, cost-efficient way for companies to leverage automation across the enterprise while protecting existing investments.

Emerson’s Project Beyond will tackle this challenge by creating a flexible, scalable and secure platform that connects today’s existing automation installed base with modern technologies to empower continuous, enterprise-wide visibility, optimisation and, eventually, autonomous operations. Project Beyond will also provide a consistent platform to deploy and manage new AI applications and models, along with contextualised data, to unlock unimagined flexibility, safety, sustainability and performance for essential industries such as energy, power, life sciences, chemical and mining.

“Companies are eager to modernise automation and keep pace with the promise of new technologies like AI without ripping and replacing their existing infrastructure or dealing with the pain and costs of integrating new applications and millions of fragmented data points,” said Ram Krishnan, chief operating officer at Emerson. “Project Beyond will use the power of software-defined control to introduce an entirely new, scalable, seamlessly integrated infrastructure with automated data contextualisation to turn trapped data into powerful operational efficiencies.”

Evolved from its industry-leading DeltaV distributed control system, AspenTech’s leading software portfolio and Boundless AutomationSM vision, Emerson’s new connected industrial technology platform will reduce the costly and complex technology integration required to move data across different operational technology (OT) systems and applications, helping customers deploy and scale new capabilities faster.

“By combining Emerson’s automation capabilities with AspenTech’s deep software expertise – from modelling and optimisation to machine learning and AI – we’re embedding artificial intelligence into our systems, turning information into insights that will help our customers along their journey toward optimised autonomous operations,” Krishnan said.

The building blocks of Project Beyond include:

• Modern Computing Environments: Project Beyond will unify the latest in on-premises edge computing with the power of the cloud to deliver unparalleled data analytics.
• Networking & Connectivity: Secure connectors, APIs and software interfaces that allow connectivity of existing OT systems, devices and legacy I/O to the platform as well as the ability to connect the platform to IT environments.
• DataOps: A powerful data fabric weaving together all OT assets, from devices to entire systems, turning contextualised data and codified knowledge into digital intelligence around operations.
• App Marketplace: A catalogue of state-of-the-art applications, curated for an organisation’s unique needs, collected in a single marketplace for easy access and deployment.
• AI Orchestration: An orchestration engine that will manage the deployment and lifecycle of AI agents enabling the future human/AI hybrid workforce.
• Zero-Trust Security Architecture: A security plane that secures every access, device, application, connection and data within the platform.

Designed as a data-centric platform, the enterprise operations platform enables a more flexible deployment of even more powerful mission-critical functionality, such as the new DeltaV IQ Controller. This software-defined controller will run on commercial, off-the-shelf servers, bringing increased scalability, flexibility, resiliency and extensibility to enterprise operations.

“Emerson has never been content to incrementally improve on current offerings, especially today with the tremendous opportunities around industrial AI,” said Krishnan. “Project Beyond is designed to make it easier and more cost-effective to access the data you need to unleash new AI applications and future-proof your industrial automation investments.”

www.emerson.com/en-us/expertise/automation/enterprise-operations-platform

BYD Auto Company, a leading Chinese new energy vehicle manufacturer, is among the first Chinese car manufacturers to establish a factory in Europe. Dürr has supplied more than 120 painting and handling robots to the Hungary plant, offering environmentally friendly and efficient painting solutions for electric vehicles. The plant’s painting lines are equipped with Dürr's EcoRP series robots in both 6-axis and 7-axis models, automating interior and exterior painting in coordination with handling robots. The 7-axis robot also assists with opening the hoods, while the 6-axis robot efficiently paints the exterior of the vehicles.

BYD has adopted Dürr's EcoBell3 high-speed rotary atomiser to ensure flawless painting quality with uniform shade, flow, and layer thickness. In combination with advanced environmental and color-changing technology, the atomiser family enables fast color changes and reduces energy consumption. The integration of the standardised and modular EcoSupply P special paint system from Dürr will further increase efficiency. The piggable system returns paint residue to the container, leaving no residue. This significantly reduces both paint and solvent residue.

For BYD's various EV models, Dürr has customised flexible-action feather rollers cleaning robots to efficiently remove dust and dirt particles from complex body surfaces.

www.durr.com/en

This agreement marks a significant milestone in an already successful collaboration, which began in 2018 and has since delivered tangible improvements in logistics automation. DHL Supply Chain, the Group's contract logistics division, has led the way, introducing Stretch commercially in North America in 2023 and more recently expanding deployments to the United Kingdom and across Europe.

To date, the deployments of Stretch have achieved case unloading rates of up to 700 cases per hour and contributed to higher employee satisfaction by reducing the need for physically demanding work in hot or cold trailers. The partnership has also driven joint product development with end-to-end automation solutions integrating conveyors and palletisers, as demonstrated in the UK project. To further build on these successes, DHL Group is actively exploring how the technology can benefit other business units. A key priority is case picking – the most labour-intensive activity within DHL Supply Chain – which represents the next major development to maximise the impact of Stretch beyond container unloading.

"Through our Accelerated Digitalisation agenda, we are committed to maximising the impact of robotics and automation across all our operations and business units," said Sally Miller, Global CIO of DHL Supply Chain. "It's a fundamental shift that's reshaping how we operate and elevate service for our customers. Through this expanded partnership with Boston Dynamics, DHL will take a more active role in shaping and directing robotics development alongside key partners, focusing on building more resilient, responsive and smarter solutions that address the unique challenges of our company. Together, we're setting new standards for the logistics industry."

Cross-business innovation

As part of its commitment to cross-business innovation, DHL ensures that successful advancements developed within the Supply Chain division are evaluated and adapted for implementation across the wider Group, maximising impact at scale.

Over the past three years DHL Group has invested over €1 billion in automation in its contract logistics division alone. Across its global network, the Group now uses more than 7500 robots, over 200,000 smart handheld devices, and close to 800,000 IoT sensors to optimise operations, enhance working conditions for employees, and deliver measurable value for customers. Today, more than 90% of DHL warehouses worldwide are equipped with at least one automation or digitalisation solution.

DHL is bolstering its industry-leading automation strategy by placing greater emphasis on co-developing solutions with both new and established robotics partners, rather than relying solely on off-the-shelf technologies.

The DHL and Boston Dynamics partnership model achieves that. DHL Group offers real-world operational environments as a proving ground for advanced technologies, providing critical feedback and industry-specific insights. Moving beyond a traditional vendor relationship, the companies will jointly develop, test, and scale solutions in real-time operations. This allows DHL to focus on their core logistics strengths, while the world's leading robotics innovators create tailor-made technologies for the company's and the logistics industry's needs. This open, operationally integrated approach also allows DHL and Boston Dynamics to jointly advance solutions like Stretch, while also exploring further synergies across divisions.

First multi-use case, box picking robot

Robert Playter, CEO of Boston Dynamics, commented: "We are proud to continue strengthening our collaboration with DHL Group. Our teams have been on a journey of innovation together to create a practical and effective warehouse robotics solution, and this is the natural next step in what has been an excellent relationship. Stretch is ideally suited to be the first multi-use case, box picking robot that can meet the diverse needs of DHL. Together we are striving to set an example of practical leadership of the modern supply chain."

As part of Strategy 2030, DHL Group aims to further formalise its partnerships with technology leaders, driving not just deployment at scale, but also joint development, co-investment, and deeper collaboration models. This integrated approach – ranging from robotics partnerships to mutually beneficial incentive programs – will play a central role in establishing robotics and automation as key drivers of sustainable, long-term growth across DHL Group.

group.dhl.com/en

Robert Peters launched KC Machine Movers in 2021 with his business partner Kevin Hill. The specialist machinery installation and equipment relocation service provider offers cutting edge solutions for the end-to-end installation of machinery. The company also has a team of highly skilled mechanical and pipe fitters and electrical engineers who can carry out installation, fitting and testing where required.

Originally starting with three members of staff, in the four years since its inception, the company has grown to a team of 40. It provides a range of services across a diverse client list working on complex projects, including Formula 1 teams, industrial plants, aerospace companies and defence contractors across the UK and Europe. It expects to achieve turnover of £5m in the coming financial year, all with the aid of eCapital.  

Invoice finance

The secret behind its growth story is invoice finance, a cashflow solution that allows organisations to release cash from outstanding invoices. It not only provides fast access to immediate cash but also an ongoing source of funding which grows as a business grows – a key requirement for startups and scaling businesses keen to make their mark.

How it works is simple: invoice finance uses receivables (invoices) as the principal asset against which money can be raised. The invoice financer pays the client an agreed percentage of the invoice value (typically 85% of the invoice value) as soon as it is submitted. As a result, businesses can build a revolving line of credit and gain quick access to cash while waiting for customers to pay their invoices.  

Working across complex clients, and industries, Peters understood the need for a cashflow solution that allowed him to build relationships and trust with key prospects and clients: “eCapital has been supporting the growth journey of KC Machine Movers from pretty much the beginning. Ours is a traditional industry with weekly pay, but some of the projects we work on are 60-, or 90-day invoicing, so we needed certainty and the ability to access cash immediately. The projects we work on can be complex, so we need cash available to us.” 

He adds: “eCapital are adaptable to our needs, allowing us to flex up, and flex down what we need from them. In the nearly four years we’ve been with them, they’ve not baulked at anything  that we’ve asked. eCapital has really taken the time to understand us as a business. We speak most days and also have the ear of the senior team which we can lean on if we need it.”

Growth and expansion

The relocation and machine moving service has been able to grow and expand into new territories, all because of the bespoke financing solution that eCapital provides. “A recent job saw us dismantling and moving a manufacturing line from Germany to the UK as part of a complete factory closure project,” Peters explained, adding: “This eighteen-month project included full-scale dismantling rigging and lifting of machinery, equipment and transport,  as well as shipping some machinery across to the USA. This project was only possible because of the financing from eCapital.”  

The machine moving company has been on a steady upward trajectory since its launch, and the partnership with eCapital has grown.  The next stage for KC Machine Movers is its own site, as Peters explains: “We are now firmly established within the industry and the next stage of our growth is our own premises, which
 we’re on track for within the next 12-18 months, because of the finance solution that eCapital offers us. With their support we have expanded from our initial Doncaster base to two 10,000 ft warehouses in Sheffield.”  

Eileen Creely, regional managing director, North of England is committed to maintaining the excellent relationship with KC Machine Movers: “As a dedicated funding partner, we've had the privilege of witnessing KC Machine Movers' tremendous evolution firsthand. Throughout our relationship, we've taken pride in providing tailored financial support and strategic guidance that has contributed to their success. Looking ahead, we remain steadfastly  committed to standing by KC Machine Movers' side as they pursue ambitious expansion plans. Our team is ready with the bespoke, flexible solutions needed to help them achieve their vision and continue their remarkable upward trajectory.”  

ecapital.com/en-gb/

    

The VVT Prioritisation Tool, created by Dr Khadija Tahera at The Open University, is a free, interactive online platform that helps engineers align verification, validation and testing (VVT) strategies with customer requirements, regulatory standards, and business objectives. It offers a smarter way to plan and prioritise product testing, potentially saving time and reducing development costs.

It was developed with the support of InterAct, the Made Smarter Innovation programme that brings together economic and social scientists, UK manufacturers, policymakers, and digital technology providers to address the human issues resulting from the diffusion of new technologies in industry.

Traditional VVT methods often focus too narrowly on technical risks, primarily reflecting the perspective of engineers. However, Dr Tahera’s research highlights the importance of integrating the voices of the customer, regulator, and business to ensure comprehensive, effective testing strategies.

Her research led to the development of an innovative tool that brings previously siloed testing methodologies – Quality Function Deployment (QFD), Failure Modes and Effects Analysis (FMEA), and Design Verification and Validation Plans (DVP&R) – into a unified, user-friendly platform.

It guides engineers through a seven-step process that helps prioritise tests, make data-driven decisions and plan necessary tests, offering a dynamic solution to effective testing in product development. Users can also simulate changes and visualise how shifting priorities impact outcomes.

Dr Tahera said: “Testing can account for up to 75% of a product’s development budget. This tool simplifies a complex process into a clear, repeatable approach. It encourages teams to challenge assumptions and work collaboratively to improve quality, reduce cost, and ensure compliance.

“Though still in prototype, the tool is powerful, scalable, and promotes smarter, faster decision-making. I believe manufacturers of all sizes can benefit from exploring its potential.”

The tool is available at smart-testing.open.ac.uk and is already attracting interest from engineering solution providers and manufacturing companies.

InterAct was a £4.4 million Made Smarter Innovation-funded, Economic and Social Research Council-led network that brought together economic and social scientists, UK manufacturers, policymakers, and digital technology providers to address the human issues resulting from the diffusion of new technologies in industry.

With involvement in over 70 events both in-person and online, welcoming more than 2,000 stakeholders to engage and connect, InterAct has placed building the Network at the heart of their activities. With more than 750 network members, the community has proven to be a dynamic bridge between industry, policy and academia.

InterAct funded 30+ projects spanning topics from Digital Change Management to sustainable steel manufacturing and public perceptions of manufacturing, bringing together 100+ researchers from more than 40 institutions.

InterAct also collated insights for UK manufacturing from the global manufacturing environment, leading research missions to engage with 150+ manufacturing and digital technology leaders in Singapore, Malaysia, India, Australia and Sri Lanka.

Professor Jillian MacBryde of the University of Strathclyde, co-director of InterAct, said: "We are immensely impressed with Dr Tahera's pioneering research which offers a transformative approach to the VVT process. It has the potential to reshape how manufacturing industries approach product development, ensuring that products meet the highest standards of quality and safety but also drive down costs by addressing risks more efficiently.”

For more information about the VVT Prioritisation tool visit smart-testing.open.ac.uk

For more information about the work of InterAct visit interact-hub.org

Modern computer vision technology is enabling sortation to be automated, removing staff from mundane operations and allowing them to carry out more complex tasks. The use of optical character recognition enables parcels to be quickly scanned and assigned to a bin that will collate all the packages for a delivery area. Automation allows line speeds to be increased and reduces sorting errors, boosting efficiency.

As volumes have increased, so too has the variety of packages. The use of plastic polybags for clothes and small items has also introduced problems for conveyor systems using rollers that can trap or damage some items. This can be overcome by using totes, but the additional investment and work required to transfer the boxes onto and off the conveyors can reduce productivity. At the same time, the variety of package shapes and weights has also increased, making the sortation process even more complex.

The solution to overcoming these challenges lies with a conveyor system that can handle the vast majority of packages and quickly divert them to the next part of their journey. Rollertop belts are the most effective and safest method of sorting packages. Having identified the destination from the barcode, zip code or hand-written address, the warehouse management system communicates with the rollertop belt equipped sorting modules, which move the package along the conveyor system and divert it into the correct delivery bin.

Beyond the improved efficiencies, rollertop belts equipped soring modules, such as Regal Rexnord’s Modsort range, are also optimised for safety, powered by a 24-volt supply they also ensure operators are protected from injury as they can be stopped by hand, which also minimises the risk of damage to the packages. Furthermore, they are quiet, so operators do not need to wear hearing protection when working around the conveyor system.

Minimising process footprints

Beyond the sorting process, transporting all the packages around the facility requires hundreds of meters of conveyor systems including curves, which help to minimise the footprint of the equipment. One of the challenges with traditional belted curves is the variety of belt lengths and widths that need to be held for spare parts.

However, Regal Rexnord has overcome this issue with its RCS1540 curve system, which uses multiple tracks equipped with a modular chain which can be configured for any curve up to 180 degrees. It offers a compact footprint, the same angular speed for each track and minimal spare parts holding requirement. Standardised with the rest of the case handling portfolio, this modular system is easy to configure and cost-effective to maintain.

Introducing automation to an existing facility may seem to be a daunting task as there is a perception that it could involve many suppliers delivering the varied aspects of the project. However, engaging with one source that is capable of delivering integrated solutions from numerous brands, each with their own specialist knowledge and products for logistics, can significantly simplify project delivery.

Logistics operations are integral to all manufacturing processes enabling finished products to be shipped to customers; from individual packaging to palletising and onward delivery, speed and reliability are key to an efficient process. Central to achieving a high level of automation is integrating the individual components tailored to the application.

Regal Rexnord combines a range of brands, each with their own expertise, enabling customers to specify complete logistics solutions tailored for their particular application. An experienced team of logistics engineers can design a system with the capacity, speed and efficiency expected in today’s demanding market. Providing modular systems that integrate seamlessly to deliver a turnkey solution, Regal Rexnord is unlocking the performance and reliability that is required for tomorrow’s logistics operations.

RegalRexnord.com

Funded by Innovate UK, this £1m, 16-month programme has achieved significant advancements in recycling waste copper into high-purity copper powder feedstock for high-value applications, paving the way for a sustainable UK-based manufacturing supply chain.

Key achievements include demonstrating innovative processes to consolidate, refine, and atomise waste copper, followed by oxygen reduction of the powder, yielding remarkable results:

• Cost-Effective Consolidation: MTC briquetting has emerged as the most economical method for consolidating copper waste, enabling competitive pricing of £15-£20/kg for 99.9% purity copper. ​
• Refinement: Aeramine’s vacuum induction melting technology refines copper to an impressive purity of 99.997% while achieving energy savings of over 50% compared to traditional methods.
• Atomisation: PSI successfully atomised copper feedstock, resulting in a 60% reduction in oxygen content, decreasing it from 250 ppm to 100 ppm, and producing powder suitable for advanced manufacturing applications.
• Fluidised Bed Processing: PSI achieved a further significant reduction of oxygen in the powder, from 100 ppm to 40 ppm, by utilising an innovative powder processing technology, resulting in market-leading ultra-low oxygen powders for demanding applications.
• Additive Manufacturing: Demonstrations utilising Laser Powder Bed Fusion (PBF-LB) and Cold Spray Additive Manufacturing (CSAM), conducted by MTC, highlighted the viability of recycled high-purity copper powder for high-performance applications, including heat exchangers, aerospace, and automotive components. ​

High-purity copper produced through the Pure CuRE process is also ideal for applications in advanced electronics, medical engineering, and cryogenic systems. The project’s success establishes the UK as a leader in sustainable copper recycling, with the potential for expansion into rare earth metals and other high-value materials.

Alex Lapis, co-founder and managing director at Aeramine, said: “Our vacuum refinement technology has proven its capability to deliver ultra-high purity copper efficiently. ​ We’re excited to scale this innovation and explore its application in other metals.” ​

Dr Tom Rehaag, research and technology manager at PSI, stated that “PSI’s versatile fluidised bed technology enables production of ultra-low oxygen powders for the most demanding applications, and offers an invaluable solution for powder users to rejuvenate old out-of-spec powders back to as-new condition.”

Dr Steven Hall, materials technology technical specialist at MTC, commented: “Pure CuRE has demonstrated a major advancement in upcycling scrap copper into high-purity formats, supporting the creation of a fully circular UK-based supply chain.  Pure CuRE provides a fantastic opportunity for UK industry to leverage high-purity copper in applications such as electrification and nuclear fusion, ultimately helping reduce carbon emissions through clean energy generation.”

The Pure CuRE team is now focused on scaling up production, optimising processes, and seeking commercial partnerships to bring these innovations to market.  With a 10-year growth target, the project aims to revolutionise copper recycling and expand into other high-value materials. ​

www.aeramine.com

A digital twin is a dynamic virtual representation (‘twin’) of a physical asset, process, or system, bridging the physical and digital worlds. They turn data into real-time insights that can optimise performance, reduce costs, and predict outcomes before they happen. Since funding for the project was announced, Digital Catapult has brought together industry and innovators to identify adoption barriers and strategic interventions.

At the Centre’s opening, the project’s co-investing industry partners – Artemis Technologies, Spirit AeroSystems, and Thales UK – utilised the cutting-edge facilities, including the 360-degree immersive space and advanced technology lab, to demonstrate how digital twins are helping to solve complex operational challenges. These early-stage use cases emphasise the power of cross-sector collaboration to create scalable, practical solutions while building expertise that can be shared across industries, ultimately improving product design, building supply chain resilience, and decarbonising operations.

Programmes delivered by the UK Digital Twin Centre will help businesses across the UK to demystify, demonstrate, and deploy digital twins. With expert support, test environments and tools to experiment and validate, combined with shared learnings from industry use cases, it offers a practical route to adoption. The Centre has convened capabilities across digital twins six enabling technology areas - intelligence, data services, immersive and UX, cyber-physical systems, integration, and security - to make this emerging technology more accessible and interoperable across sectors and suppliers.

“The UK Digital Twin Centre marks a major step for Belfast, driving innovation in high-growth sectors like advanced manufacturing,” said the Lord Mayor of Belfast, Councillor Micky Murray. “Through the Belfast Region City Deal and with Digital Catapult’s UK-wide reach, we’re connecting our SMEs to a powerful network, unlocking access to new markets, collaboration opportunities, and cutting-edge technologies. This will boost local businesses, create high-skilled jobs, and drive real economic impact for the region.”

The Centre’s first six-month Accelerator Programme, now open for pre-application expressions of interest, will support partnerships between tech SMEs and industry to fast-track digital twin adoption in maritime, aerospace, and defence. Alongside Innovate UK funding, participants will also gain access to mentorship, workshops, and specialist support to develop proofs of concept for enabling technologies—such as IoT, data integration, and simulation tools— bringing their solutions closer to real-world deployment.

“The UK Digital Twin Centre brings together our technical expertise, facilities, and networks to unlock the power of deep technologies,’ said Susan Bowen, CEO of Digital Catapult. “By connecting industries with cutting-edge technology through our programmes, we are enabling businesses to harness the full potential of digital twins-driving operational efficiencies, advancing sustainability, and sharpening the competitive edge of UK businesses."

Dean Cook, executive director for place and global at Innovate UK, added: “Seeing real-world use cases coming to life at the UK Digital Twin Centre is a powerful demonstration of how digital twins can deliver tangible advances for UK industry. These cutting edge tools will solve complex business challenges in aerospace, maritime, and defence. It’s a testament to how we are leveraging the strengths of local innovation clusters across the UK, with Belfast bringing together it’s wealth of business and research expertise in digital technologies and advanced manufacturing. In turn this will have a positive impact on economic growth in Northern Ireland and across the UK.”

Expressions of interest are now open for tech SMEs and industry leaders ready to collaborate on real-world challenges on the first UK Digital Twin Centre accelerator programme at:  

digicat.org.uk/UK-Digital-Twin-Centre
 

The company reports a 30% year-on-year increase in automation opportunity assessments in Q1 2025, highlighting a strategic shift as manufacturers respond to trade barriers, supply chain disruptions, and persistent workforce challenges.

This trend coincides with recent research showing UK companies plan to invest £650 billion in reshoring initiatives over the next three years, driven by concerns over recent tariffs and supply chain vulnerabilities.

Workforce challenges drive automation adoption

The surge in automation assessments comes as manufacturers face significant workforce constraints. With the combined cost of salary and National Insurance Contributions for full-time workers on the living wage increasing by 44% since 2021 according to Oxford Economics, companies are looking to make the most of their existing talent through automation.

"What we're seeing is that companies have to be pragmatic about the reality of today's labor market," said Søren Peters, Co-CEO and founder of HowToRobot. "With persistent workforce shortages and growing costs, businesses are focusing on how their current employees can create more value through automation rather than trying to fill positions that consistently remain vacant or changing hands."

UK's automation gap presents significant opportunity

The UK currently lags behind similar economies in manufacturing automation, with just 119 robots per 10,000 manufacturing employees compared to the global average of 162 and Germany's 429, according to the International Federation of Robotics. This automation gap represents a substantial opportunity for productivity improvements.

"Many UK manufacturers are discovering significant untapped potential within their existing operations," added Peters. "Our assessments frequently identify automation opportunities that can increase capacity substantially without expanding physical footprint or headcount.”

Low-risk, high-return opportunities take priority

HowToRobot reports that manufacturers are primarily seeking automation solutions that can be implemented with minimal disruption and rapid returns. The most successful projects typically focus on supporting processes such as material handling, packaging, palletizing, and quality inspection rather than completely overhauling core production.

"The current economic climate has shifted the automation conversation from 'futuristic moonshots' to practical, proven solutions with clear ROI," said Peters. "Our discovery assessments help companies quickly identify and separate the high-value, low-risk opportunities from potentially disruptive implementations, enabling manufacturers to take confident action even amid economic uncertainty."

As supply chain challenges and reshoring trends continue, HowToRobot expects the demand for targeted automation assessments to grow throughout 2025.

Meet HowToRobot at Automation UK

HowToRobot's team of automation experts will be present at Automation UK (stand D84) in Coventry on May 7-8, 2025, to provide guidance to manufacturers exploring automation options. They will also present insights on "What Separates Automation Success from Failure" at 1:30 p.m. at Automation Theatre 2.

www.howtorobot.com