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April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 1
April 9, 2023
BRIAN STANDBRIDGEUK OPERATIONS & EMEA SOURCING DIRECTOR
IDEAL STANDARD INTERNATIONAL
OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION
14 OCTOBER 2010
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 3
Introduction
• Privately owned company employing over 10,500
• European HQ in Brussels
• Operations in Europe, Middle East, Africa and Latin Americas
• Brands
• UK - Main manufacturing warehouse site at Armitage, Rugeley
- Employing over 50% of 1,200 UK employees
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 4
Recently – the site has developed from a multi level casting facility to single level (2000). It has seen a progressive removal of all plaster moulds (the last of which was removed in 2004). Combined with the introduction of automation.
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 5
History in the UK
o1999 / 2000 Acquisition of Armitage Shanks in the UK
and Ceramica Dolomite (Italy)
o2000 – to date Consolidation of ‘general purpose ’
sites
o£7.5m manufacturing investment and
£2.5m warehouse investment
oFocused Commitment of American owners to plant in
Armitage village (Rugeley) on producing bulk of UK
sales in a single plant.
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 6
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 7
Key Strategy for the Plants Evolution
o Conversion to 100% pressure casting facility (UK &
Italy)
o Installation of 3 generation of pressure casting
equipment based on technology available
1. Pressure Cast – manual demoulding/finishing
2. Pressure Cast – robot demoulding / manual finishing
3. Pressure Cast – 100% robot demould / finishing
o 24x7 Plant – 350 days / year
o Balanced flow – all machines integrated in flowline
production facility with transportation elimination
and 100% robotic glaze application
o Installation of best practise recycling equipment
for glaze usage.
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 8
Key Strategic aims …
Equipment installed in quest of strategy of:-
Highest productivity plant in ISI
Lowest material usage – highest yield and zero waste
Tighter process control – quality and yield
Produced locally, sold locally, supported locally
Lowest carbon footprint (UK manufactured)
Cost position towards goal of « CHINA + SHIPPING »
2000 20022001 2003 2004 2005 2006 2007 20092008
Pre 2000Dorst & Porvair basin pressure
casting machines
16 x glaze application robots
Bead milling Glaze preparation
unit
1 x Porvair 4 part bowl
Pressure casting
machine
1 x Porvair 4 part bowl
Pressure casting
machine1 x Porvair 5
part bowl
Pressure casting
machine
Xtract glaze reclamation
unit
SACMI automated tank cell
1 x Porvair COBR & WHB
Pressure casting
machine
1 x Porvair FFC basin & ped
Pressure casting
machine
492 451 395 378 323 303 306 300 297 286
Headcount reduction ( redeployment/natural wastage / voluntary)
Capacity growth from 1,35m to 1,9m pcs (+40%)
Introduction of new technology
Continuous Introduction of Footprint
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 10
KEY ACHIEVEMENTS – BEFORE / AFTER
TRADITIONAL
PLANT
TRADITIONAL
PLANT
CONVERTED AUTOMATED
PLANT
CONVERTED AUTOMATED
PLANTRoSPA Gold medal Winners
Reduction of recordable incidents
Over -90% Now Single Digit per year
Safety Culture
RoSPA Gold medal WinnersReduction of recordable
incidentsOver -90% Now Single Digit per
yearSafety Culture
Safety Record Poor
Claims Culture
Safety Record Poor
Claims Culture
Customer Lead Times long (2 weeks)
with backlog variation
Customer Lead Times long (2 weeks)
with backlog variation
Manufacturing leads times from5 days to below 36 hours
Inventory Reduction – 28%Mould changed daily
Next day delivery introduced
Manufacturing leads times from5 days to below 36 hours
Inventory Reduction – 28%Mould changed daily
Next day delivery introduced
Variability of QualityYields and Conformance of products
Variability of QualityYields and Conformance of products
15% higher FPYHighest FPY in Group
Return on Sales halved (Warranty)
15% higher FPYHighest FPY in Group
Return on Sales halved (Warranty)
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 11
KEY ACHIEVEMENTS – BEFORE / AFTER
TRADITIONAL
PLANT
TRADITIONAL
PLANT
CONVERTED AUTOMATED
PLANT
CONVERTED AUTOMATED
PLANTTypically 30% labour needed
Engineering based plant with Ceramic knowledge
Typically 30% labour neededEngineering based plant with
Ceramic knowledge
Manually-intensive plant.
Craft style skills
Manually-intensive plant.
Craft style skills
Mixed technologies
Batch produced
Traceability difficult
Mixed technologies
Batch produced
Traceability difficult
Standard flow technology(UK/Italian produced)
Continuous 24x7 operationsBarcoded 100% Tranxfer
production Real time fully integrated SAP
Standard flow technology(UK/Italian produced)
Continuous 24x7 operationsBarcoded 100% Tranxfer
production Real time fully integrated SAP
Energy-intensive(drying)Material intensive(Moulds, clay, waste)
Energy-intensive(drying)Material intensive(Moulds, clay, waste)
Energy consumption units/1000’s
Gas = 62% averageElectricity = 58% average
Mould life > 50k Materials = 75%
Zero waste philosophy
Energy consumption units/1000’s
Gas = 62% averageElectricity = 58% average
Mould life > 50k Materials = 75%
Zero waste philosophy
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 12
16,250
Co2/annum
Rugeley plant
Traditional plant
Asian Sourced Product
Saving
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 13
WE BELIEVE …• Made in Staffordshire
• Highest productivity and reliability
• Pride in quality and lifetime guaranteed!
• Loyal (15 year average) and skilled workforce who are keen and adaptable to change.
• Can be used in a large company ‘balance’ exchange rates
• No 25% labour inflation
• No 40% transportation inflation
• Best solution for CHINA + SHIPPING
SUMMARY
April 9, 2023OPPORTUNITIES WITH ROBOTICS AND FACTORY AUTOMATION 14
