NZ Manufacturer July 2024 by Media Hawkes Bay Limited – Issuu

Adam Sharman, Senior Partner, Dsifer

In an era where digital transformation is reshaping industries across the board, bespoke engineering and machine shops face a unique set of challenges and opportunities.

These specialised manufacturers, known for their ability to create custom, one-off products, are now grappling with how to embrace digital technologies without losing the craftsmanship that sets them apart.

As they step into this brave new world, several key considerations emerge, along with significant benefits.

At LMAC and Dsifer, we work with a lot of custom engineering organistions, and recognise the unique challenges these shops face. At the heart of the digital transformation is the need to maintain and enhance customisation capabilities, whilst optimising production and front-end processes to remain competitive on time to deliver and cost.

Bespoke engineering thrives on flexibility, and any digital system must be flexible enough to accommodate diverse client demands. Advanced product configuration tools and parametric design software are becoming essential, allowing engineers to quickly adapt designs while maintaining the personal touch that customers expect.

Data integration stands as another cornerstone of this digital revolution. By connecting design, production, and quality control systems, shops can create a seamless flow of information from concept to finished product.

Product Lifecycle Management (PLM) software is increasingly becoming the central nervous system of these operations, ensuring that every stakeholder has access to the latest information.

The adoption of advanced manufacturing technologies is reshaping the landscape, offering substantial benefits. With Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) systems well-established to significantly reduce design time and errors, additive manufacturing, opens new doors for prototyping and small-batch production, allowing for rapid iteration and reduced waste.

These technologies enable machine shops to take on more complex projects and deliver them faster, increasing competitiveness and profitability.

Digital manufacturing also brings remarkable improvements in efficiency and productivity. Machine shops can now utilise digital twin technology to simulate design and optimise production processes before physical implementation.

This leads to reduced setup times, minimised material waste, and improved overall equipment effectiveness (OEE). Real-time monitoring and data analytics enable predictive maintenance, reducing downtime and extending the life of expensive machinery.

For the workforce, while there’s a growing need for building capability uplift, digitisation also brings benefits. Digital tools can automate repetitive tasks, allowing skilled machinists to focus on more complex, value-added work. Augmented reality (AR) training tools are making it easier to transfer knowledge and skills, addressing the industry’s persistent skills gap.

Quality control, always critical in bespoke engineering, is being enhanced through digital means. Advanced inspection technologies and digital testing methods are improving accuracy and consistency.

Moreover, digital systems make it easier to maintain detailed documentation and traceability, which is particularly valuable for shops serving regulated industries like aerospace or medical devices.

Supply chain management is another area ripe for digital transformation. By digitising inventory and procurement processes, shops can reduce lead times and improve communication with both suppliers and customers. This enhanced connectivity is particularly valuable in an industry where timing and precision are everything.

As shops become more digitally integrated, cybersecurity emerges as a critical concern. Protecting intellectual property and sensitive customer data is paramount, as is ensuring the reliability and integrity of digital systems.

Machine shops must now consider cybersecurity as an integral part of their operations, not an afterthought.

The customer interface is being revolutionised, offering new ways to add value. Online platforms for order placement and tracking are becoming standard, as are digital collaboration tools that allow clients to be more involved in the design and specification process.

This increased transparency and interaction can lead to better outcomes and stronger customer relationships.

One of the most significant benefits of digital manufacturing for machine shops is the ability to tap into new business models. With digital technologies, shops can offer rapid prototyping services, engage in distributed manufacturing networks, or even provide digital design services.

This diversification can lead to new revenue streams and increased resilience in a competitive market.

As bespoke engineering and machine shops navigate this digital frontier, the key to success lies in embracing technology while preserving the unique value proposition that sets them apart.

By carefully considering these factors and implementing digital solutions thoughtfully, these shops can not only survive but thrive in the digital age. The benefits – increased efficiency, improved quality, enhanced customer satisfaction, and new business opportunities – make the digital transformation journey not just necessary, but exciting and full of potential.