How to harness collaboration for smart manufacturing

In 2017, Rolls-Royce, the Agency for Science, Technology and Research (A*STAR) and Singapore Aero Engine Services Private Limited (SAESL) established the Smart Manufacturing Joint Lab to push the boundaries of industrial, academic and business partnership. The S$60 million programme focuses on developing next-generation aerospace manufacturing, maintenance, repair and overhaul (MRO) capabilities enabled by advanced processes, automation and digital technologies. With access to the entire A*STAR network, including the Advanced Remanufacturing and Technology Centre’s Model Factory, the Joint Lab bridges teams from different institutes such as the Institute for Infocomm Research (I2R), National Metrology Centre (NMC) and Institute of High Performance Computing (IHPC).  

“The joint programme allows us to access the talent available across the A*STAR institutes together with the fantastic capabilities available at the ARTC in order to develop game-changing technology solutions for our Singapore manufacturing facilities,” said Stephen Burgess, Director, Manufacturing Technology, Rolls-Royce.

The Joint Lab’s location in Singapore also offers strategic advantages. “The Joint Lab’s proximity to our customers operating in Asia Pacific allows us to develop and deploy new innovations across manufacturing, assembly and our MRO network rapidly,” said Bicky Bhangu, President - South East Asia, Pacific & South Korea, Rolls-Royce. “Our partnership with a statutory board also means that we can align our strategies closely with the governments’ industry transformation maps, facilitating knowledge transfer and building up a technological ecosystem that benefits all parties.”

With staff that span across research institutes, the engine manufacturer and the MRO organisation, the mixture of backgrounds, experience and knowledge provides more diverse perspectives that help solve problems faster. Hence, the Joint Lab throws up more creative solutions that address industry needs.  

Problems are identified within Rolls-Royce by challenging existing processes, which triggers research and development in the Joint Lab. This allows engine manufacturers and technology developers to co-create solutions for future use, while researchers ensure their projects have an actual impact on needs on the ground.

Technological transformation takes time. The Joint Lab understands that big outcomes can only be achieved with incremental successes. Hence, it focuses not only on top-level gains but appreciates the value of short-term wins.

For instance, during one of their regular discussions, A*STAR researchers and technicians from Rolls-Royce’s Seletar Assembly and Testing Unit (SATU) discovered a more efficient method for tracking inventory. Within a few weeks, researchers tested and deployed a serial number and data matrix scanning technology on the shop floor, which was immediately used to improve efficiency and productivity while minimising risk from human error.

“The speed at which these simple improvements are implemented has alleviated many of our pain points and allows us to work towards long-term goals more seamlessly,” said Imtiaz Ahmed, Manufacturing Engineer – Capability Acquisition, Rolls-Royce. “Take the scanning technology for instance. It sped up our team’s working process and freed up our time to do more value-added tasks.”

Deploying solutions quickly also gives researchers an edge in gaining additional commitment from Government and Industry. The virtuous circle provides more tangible results to justify their business cases, giving them more confidence to help secure more research funding.

Teams from A*STAR, Rolls-Royce and SAESL work closely together at the Joint Lab, with constant discussions as well as weekly and quarterly reviews that are helping to forge a new work culture, triggering mind-set changes across all organisations when it comes to innovation and implementation.

For researchers, they will have more exposure to industry processes, helping them adopt an industry-oriented research mind-set. Technicians and managers in facilities such as Rolls-Royce and SAESL have a platform to voice issues in terms of workflow and productivity. Being looped into the conversation also allows them to see their contributions to the bigger transformation roadmap.

The availability of co-working spaces at the Joint Lab encourages frequent visits from Rolls-Royce and SAESL teams for more face-to-face discussions with the Joint Lab’s researchers. These close interactions help all parties to work through issues quickly, synchronise their plans and drive better outcomes.

“The Joint Lab is a platform where teams can voice our opinions and issues on how things can be improved and drive solutions that benefit day-to-day operations,” Kenneth said.

For research organisations such as A*STAR, the successful collaboration will also encourage other research units to adopt an application-driven mind-set. “As researchers, one of the most common pitfalls is that we can become overly invested in our projects after having spent so much time on them,” said Wang Wei, Senior Programme Manager, A*STAR. “The discussions and fast-paced approach help ensure we adopt an agile mentality,”

Tapping a wide pool of experts means that a broader range of technological and industrial issues can be solved. A successful collaborative approach will result in research and development outcomes that meet needs across the value chain.

For the Joint Lab specifically, it will help drive beneficial outcomes in the following areas:

1. Advanced Fan Blade Manufacturing: Automate value chain to drive productivity
2. Smart Assembly Systems: Apply intelligent automation across assembly operations and processes
3. Future Manufacturing Processes: Develop advanced processes like additive layer manufacturing and special processes modelling
4. Knowledge-Based Manufacturing: Use digital methods to improve quality, cost-efficiency and delivery performance
5. Integrated Remanufacturing Technologies: Explore advanced repair and remanufacturing methods including machine vision and adaptive technology

Apart from driving these technology streams, the results will create an innovative ecosystem with benefits for more industries. More businesses will benefit from better productivity and efficiency. There will also be more opportunities for skills development, helping to minimise the talent gap. Transformations in Singapore will percolate to global units in Rolls-Royce, which will develop technology to benefit the region—and the world.