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Transforming Manufacturing
The Common Challenges for the European Manufacturing Industry

The European Union (EU) is home to more than 26 million companies of which 10% are manufacturing based.   These 2.5 million manufacturing companies, more than 95% of which are small medium enterprises SMEs, employ over 36 million people and contribute approximately 22% of the EU gross domestic product (GDP).   In addition, it is estimated that in total around 75% of the EU GDP and 70% of employment in Europe is related to manufacturing as a direct result of manufacturing related service companies i.e. for every job in manufacturing there are two linked jobs in manufacturing related services.    Any reduction in manufacturing capacity in Europe therefore, is likely to have a significantly negative socio-economic impact.  To quote from the EC report ‘MANUFUTURE – A Vision for 2020’, “an economy based on service industries alone will not survive in the longer term”.

The European manufacturing industry is facing increasing competition on two main fronts.  In the high technology sector, where productivity and innovation are key, Europe faces increasing competition from developed countries such as the US and Japan. For products where cost competition predominates, manufacturing jobs are gradually being eroded and moving to low wage economies that are able to produce lower cost products.

It is the former sector (high technology added value products) that offers Europe the platform for a sustainable and competitive manufacturing industry.    Since the early 1990’s, however, and for the first time in post war years, productivity rates in Europe fell considerably behind the US and Japan (according to a study by van Ark), both of which displayed significant productivity growth versus falling productivity rates in Europe.  The study by van Ark investigates productivity in three groups of companies in both the US and Europe; Information Computing Technology (ICT) producing (those that manufacture ICT related products), ICT (using companies that use ICT for products and/or services) and non ICT (those that have low utilisation of ICT) and demonstrates that productivity growth in ICT-using industries is much higher in the US than in the EU (approximately double) emphasising an under utilisation of ICT in Europe.

Not only is Europe under utilising ICT in its manufacturing sectors, but also spends less on research and development (R&D) than it's leading major competitors (US and Japan) who spend 30% of their research effort on ICT in contrast to Europe’s 18%. More concerning is that Europe’s per capita expenditure on ICT research will soon be surpassed by China and Korea; low wage economies with an aspiration to compete in high technology added value products and services.

A study carried out by The Economist endorses the link between ICT and growth in developed countries.   It suggests that ICT accounts for the majority of Europe’s lag behind the US in growth performance in recent years with as much as 80% of the difference in growth attributed to poorer ICT exploitation.  Europe’s weakness is most acute among SMEs (more than 95% of Europe’s companies).

It is, therefore, essential that the European manufacturing sector undergoes dramatic transformation over the next two decades. The drivers for this change include:
  • Globalisation and an increasingly competitive business environment
  • Environmental issues and sustainability
  • Societal values and public acceptance of technology
  • The regulatory environment and the system of European governance
  • Advances in science and technology

These drivers will result in the following challenges:

  • Increasing supply chain efficiency
  • Minimising the environmental burden of production and consumption
  • Integrating new knowledge and improving workforce skills
  • Anticipating new market and societal needs
 
ISTAG believes that if Europe’s future is not to be one of managing decline then it must rebuild its economy and society to meet the challenges of the 21st Century.

Only by enthusiastically embracing the constitutive effects of ICT in all areas of our economy and society will Europe and Europeans achieve their true potential. Only ICT can deliver productivity increases across all economic sectors; only ICT allows us to find radically new solutions to Europe’s major societal problems; and only ICT enables citizens and business to unlock creativity and innovation.

We must grasp the opportunities ICT presents us to shape the answers to Europe’s specific needs and to remain one of the world’s most competitive regions. A renewed effort in research and innovation in ICT is essential to this task.

ISTAG Report
Shaping Europe’s Future Through ICT, March 2006
The potential of ICT to address these challenges is significant, with the ISTAG report suggesting that ICT is no longer an enabling technology but a ‘constitutive technology’ that not only enables us to do new things but shapes how we do them.

ICT Transformation of Manufacturing

Much work has already been done to identify which areas of ICT will have the most impact on the future of manufacturing.   The conclusions of the ManVis study clearly states that ICT is a key cross cutting technology and that it is a fundamental foundation for improved competitiveness in the manufacturing industry.        

The final report suggests that competition from low wage economies will prevail in the foreseeable future. ICT can, however, minimise the inevitable decline of European manufacturing by cost reduction technologies such as automation and enhanced labour productivity.

High technology manufacturing will be based on the efficient use of sophisticated manufacturing technologies, such a nano-technologies, smart materials and highly automated operations. These will be dependent on close links with the science base. It is predicted, however, that such activity will increase productivity at the expense of employment and, at best, only maintain current employment levels in high technology manufacturing.   

More strategic opportunities lie in the development and implementation of new business models and manufacturing paradigms. For example:

Local Manufacturing Operations and Local R&D to Address Local User Needs
Based on sustainability and societal issues, this concept aims to minimise transportation of material and people by having small manufacturing units close to the potential users, and which will also allow new models of high value added services to be delivered. This will potentially involve centralised design and administrative functions with integrated vertical and horizontal supply chains; possibly even the integration of competitive supply chains.    Knowledge sharing will be critical to the success of this model and ICT will be required to support such knowledge intensive operations, allow end-users access to the design process and to facilitate post sales servicing.

Eco-Sustainable Manufacturing
Societal attitude and environmental legislation may drive a manufacturing model based on eco-sustainability. This will involve new products that are designed to maximise life cycle sustainability, new materials that are eco-friendly, energy efficient manufacturing / product usage and minimised transportation throughout the supply chain.   ICT areas such as tagging and traceability coupled with complex customer interaction databases will be essential for such a model to be successful. 

Innovation System Best Practice
This comprises user interaction, product development, production, supply chain and logistics. This will require innovative and adaptive lead markets if European industry is to be the first to learn if it has an effective user/customer interaction mechanism in order to exploit this advantage, which is believed to be the most promising way in which to gain sustainable competitive advantage. ICT will be critical for such knowledge intensive industries in all aspects of business.

ICT thematic areas that are supportive of this staged transformation of European manufacturing through the development and implementation of new business models include:
  • Adaptive Manufacturing
  • Networking in Manufacturing (ie Enterprise Networking)
  • Digital, Knowledge-based Engineering (including simulation)
  • Emerging Technologies
  • ICT for Manufacturing
 
The scope of future ICT research should be to ensure a prosperous manufacturing industry in Europe whilst pursuing as a primary objective world leadership in agile, intelligent manufacturing of customised high-value goods, a key export factor of Europe’s manufacturing industry.

Report of Five Expert Panels

ICT for Manufacturing
March 2005
Source: IMS Website