Author: Dr Lampros Litos (Cranfield University). 

Topic: Sustainability in manufacturing. 

Tool type: Guidance. 

Engineering disciplines:  Aeronautical; Manufacturing, Mechanical. 

Keywords: Energy efficiency; Factories; Best practice; Eco-efficiency; Practice maturity model; AHEP; Student support; Sustainability. 

Sustainability competency: Critical thinking; Integrated problem-solving.

AHEP mapping: This resource addresses two of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): The Engineer and Society (acknowledging that engineering activity can have a significant societal impact) and Engineering Practice (the practical application of engineering concepts, tools and professional skills). To map this resource to AHEP outcomes specific to a programme under these themes, access AHEP 4 here and navigate to pages 30-31 and 35-37. 

Related SDGs: SDG 9 (Industry, innovation, and infrastructure); SDG 12 (Responsible consumption and production). 

Reimagined Degree Map Intervention: More real-world complexity.

 

Learning and teaching notes: 

The following are a set of use cases for a maturity model designed to improve energy and resource efficiency in manufacturing facilities. This guide can help engineering educators integrate some of the main concepts behind this model (efficient use of energy and resources in factories in the context of continuous improvement and sustainability) into student learning by showcasing case study examples.   

Teachers could use one or all of the following use cases to put students in the shoes of a practicing engineer whose responsibility is to evaluate and improve factory fitness from a sustainability perspective.  

 

Supporting resources:  

 

Factory assessment in multiple assembly facilities for an aircraft manufacturer:

The assessment is part of the following use case on this industrial energy efficiency network (IEEN): 

The company operates in the aerospace sector and runs 11 manufacturing sites that employ approximately 50000 people across 4 European countries. Most of the sites are responsible for specific parts of the aircraft i.e. fuselage, wings. These parts once manufactured are sent to two final assembly sites. Addressing energy efficiency in manufacturing has been a major concern for the company for several years.  

 

It was not until 2006 that a corporate policy was developed that would formalize efforts towards energy efficiency and set a 20% reduction in energy by the year 2020 across all manufacturing sites. An environmental steering committee at board level was set up which also oversaw waste reduction and resource efficiency. The year 2006 became the baseline year for energy savings and performance measures. Energy saving projects were initiated then, across multiple manufacturing sites. These were carried out as project-based activities, locally guided by the heads of each division and function per site.  

 

A corporate protocol for developing the business case for each project is an initial part of the process. It is designed to assign particular resources and accountabilities to the people in charge of the improvements. Up to 2012, improvement initiatives had a local focus per site and an awareness-raising character. It was agreed that in order to replicate local improvements across the plants a process of cross-plant coordination was necessary. A study on the barriers to energy efficiency in this company revealed three important barriers which needed to be addressed: 

  • Lack of accountability: The site energy manager is responsible for reducing the site’s energy consumption but only has authority to act within a facility’s domain–that is, by improving facilities and services, such as buildings and switchgear. They are not empowered to act within a manufacturing operations parameter. Therefore, no one is responsible for reducing energy demand.  
  • No clear ownership: Many improvements are identified but then delayed due to a lack of funding to carry out the works. This is because neither facilities nor manufacturing operations agree whether the improvement is inside their parameter: typically, facilities claim that it is a manufacturing process improvement, and operations claim that any benefit would be realized by facilities. Both are correct, hence neither will commit resources to achieve the improvement and own the improvement. 
  • No sense of urgency: A corporate target exists for energy reduction–but the planned date for achieving this is 2020.  

The solution that the environmental steering committee decided to support, was the creation of an industrial energy efficiency network (IEEN). The company had previously done something similar when seeking to harmonize its manufacturing processes through  process technology groups (Lunt et al., 2015). This approach consists of each plant nominating a representative who is taking the lead and coordinating activities. It is expected that the industrial network would contribute to a significant 7% share out of the 20% energy reduction target for the year 2020 since its establishment as an operation in 2012.  

 

The network’s operations are further facilitated with corporate resources such as online tools that help practitioners report and track the progress of current projects, review past ones, and learn about best-available techniques. This practice evolved into an intranet website that is further available to the wider community of practitioners and aims to generate further interest and enhance the flow of information back to the network. Additionally, a handbook to guide new and existing members in engaging effectively with the network and its objective has been developed for wider distribution. These tools are supported by training campaigns across the sites.   

 

Most of the network members also act as boundary spanners (Gittell and Weiss, 2004) in the sense that they have established connections to process technology groups or they are members of these groups as well. This helps the network establish strong links with other informal groups within the organization and act as conductor for a better flow of ideas between these groups and the network. Potentially, network members have a chance to influence core technology groups towards energy efficiency at product level.  

 

On average, a 5-10% work-time allocation is approved for all network members to engage with the network functions. In case a member is not coping in terms of time management there is the option of sub-contracting the improvement project to an external subcontractor who is hired for that particular purpose and the subcontractor’s time allocation to the project can be up to 100%.  

 

 “….by having the network we meet and we select together a list of projects that we want to put forward to access that central pot of money. So we know roughly how much will be allocated to industrial energy efficiency and so we select projects across all of the sites that we think will get funded and we put them all together as a group…so rather than having lots of individual sites making individual requests for funding and being rejected, by going together as a group and having some kind of strategy as well…” 

 

Each dot on each of the model rows represents the relative efficiencies that a factory achieves in saving energy and resources through best practice (5 of 11 factories represented here, each delivering an aircraft part towards final assembly). The assessment allowed this network of energy efficiency engineers and managers to better understand the strengths and weaknesses in different factories and where the learning opportunities exist (and against which dimension of the model). 

 

2. The perception problem in manufacturing processes and management practice:

The following assessment is performed in a leading aerospace company where two senior engineering managers (green and orange lines) find it difficult to agree on the maturity of different practices currently used at the factory level as part of their environmental sustainability strategy.  

This assessment was part of the following use case: 

The self-assessment was completed by the head of environment and one of his associates in the same function. These two practitioners work closely together and are based in the UK headquarters. Even though the maturity profiles do not vary significantly (1 level plus or minus) it is clear that there is very little overall agreement on the maturity levels in each dimension.  

 

3. Using the maturity model as a consensus building tool in a factory:

Seven practitioners from different parts of the business (engineering, operations, marketing, health and safety etc.) were brought together to understand how they think the factory performs. The convergence between perceptions was very small and this would indicate high levels of resistance to change and continuous improvement. For example, if senior managers think they are doing really well, they will not invest time and effort in better practices and technologies. 

A timeline (today +5years) was used to understand where they think they are today and where they want to be tomorrow.  

This can be one of the ways of thinking about improvements that need to occur, starting with areas of interest that are underperforming and developing the right projects to address the gaps. 

 

References: 

Lunt, M.F. et al. (2015) ‘Reconciling reported and unreported HFC emissions with  Atmospheric Observations’, Proceedings of the National Academy of Sciences, 112(19), pp. 5927–5931.  

Gittell, Jody & Weiss, Leigh. (2004). Coordination Networks Within and Across Organizations: A Multi-level Framework. Journal of Management Studies. 41. 127-153. 

 

Appendix:

1. High resolution picture of the maturity model for printing (also available here: Litos, L. (2016). Design support for eco-efficiency improvements in manufacturing p. 218.)

 

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.  

Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters. 
 
 
To view a plain text version of this resource, click here to download the PDF.

Author: Dr. Jemma L. Rowlandson (University of Bristol). 

Topic: Achieving carbon-neutral aviation by 2050.  

Tool type: Teaching. 

Relevant disciplines: Chemical; Aerospace; Mechanical; Environmental; Energy.  

Keywords: Design and innovation; Conflicts of interest; Ethics; Regulatory compliance; Stakeholder engagement; Environmental impact; AHEP; Sustainability; Higher education; Pedagogy; Assessment. 
 
Sustainability competency: Systems thinking; Anticipatory; Critical thinking; Integrated problem-solving; Strategic; Collaboration.

AHEP mapping: This resource addresses two of the themes from the UK’s Accreditation of Higher Education Programmes fourth edition (AHEP4): The Engineer and Society (acknowledging that engineering activity can have a significant societal impact) and Engineering Practice (the practical application of engineering concepts, tools and professional skills). To map this resource to AHEP outcomes specific to a programme under these themes, access AHEP 4 here and navigate to pages 30-31 and 35-37. 

Related SDGs: SDG 7 (Affordable and Clean Energy); SDG 9 (Industry, Innovation and Infrastructure); SDG 12 (Responsible Consumption and Production); SDG 13 (Climate Action). 
 
Reimagined Degree Map Intervention: More real-world complexity; Active pedagogies and mindset development; Authentic assessment.

Educational aim: Apply interdisciplinary engineering knowledge to a real-world sustainability challenge in aviation, foster ethical reasoning and decision-making with regards to environmental impact, and develop abilities to collaborate and communicate with a diverse range of stakeholders. 

Educational level: Intermediate. 

 

Learning and teaching notes: 

This case study provides students an opportunity to explore the role of hydrogen fuel in the aviation industry. Considerable investments have been made in researching and developing hydrogen as a potential clean and sustainable energy source, particularly for hydrogen-powered aircraft. Despite the potential for hydrogen to be a green and clean fuel there are lingering questions over the long-term sustainability of hydrogen and whether technological advancements can progress rapidly enough to significantly reduce global carbon dioxide emissions. The debate around this issue is rich with diverse perspectives and a variety of interests to consider. Through this case study, students will apply their engineering expertise to navigate this complex problem and examine the competing interests involved.  

This case is presented in parts, each focusing on a different sustainability issue, and with most parts incorporating technical content. Parts may be used in isolation, or may be used to build up the complexity of the case throughout a series of lessons.  

Learners have the opportunity to: 

Teachers have the opportunity to: 

 

Supporting resources:  

 

Learning and teaching resources: 

Hydrogen fundamentals resources: 

We recommend encouraging the use of sources from a variety of stakeholders. Encourage students to find their own, but some examples are included below: 

 

Pre-Session Work: 

Students should be provided with an overview of the properties of hydrogen gas and the principles underlying the hydrogen economy: production, storage and transmission, and application. There are several free and available sources for this purpose (refer to the Hydrogen Fundamentals Resources above). 

 

Introduction 

“At Airbus, we believe hydrogen is one of the most promising decarbonisation technologies for aviation. This is why we consider hydrogen to be an important technology pathway to achieve our ambition of bringing a low-carbon commercial aircraft to market by 2035.” – Airbus, 2024 

As indicated in the industry quote above, hydrogen is a growing area of research interest for aviation companies to decarbonise their fleet. In this case study, you are put in the role of working as an engineering consultant and your customer is a multinational aerospace corporation. They are keen to meet their government issued targets of reducing carbon emissions to reach net zero by 2050 and your consultancy team has been tasked with assessing the feasibility of powering a zero-emission aircraft using hydrogen. The key areas your customer is interested in are: 

 

Part one: The aviation landscape 

Air travel connects the world, enabling affordable and reliable mass transportation between continents. Despite massive advances in technology and infrastructure to produce more efficient aircraft and reduce passenger fuel consumption, carbon emissions have doubled since 2019 and are equivalent to 2.5 % of global CO2 emissions.  

 

 

Your customer is interested in the feasibility of hydrogen for aviation fuel. However, there is a debate within the management team over the sustainability of hydrogen. As the lead engineering consultant, you must guide your customer in making an ethical and sustainable decision.  

Hydrogen is a potential energy carrier which has a high energy content, making it a promising fuel for aviation. Green hydrogen is produced from water and is therefore potentially very clean. However, globally most hydrogen is currently made from fossil fuels with an associated carbon footprint. Naturally occurring as a gas, the low volumetric density makes it difficult to transport and add complications with storage and transportation. 

 

 

Part two: Hydrogen production 

Hydrogen is naturally abundant but is often found combined with other elements in various forms such as hydrocarbons like methane (CH4) and water (H2O). Methods have been developed to extract hydrogen from these compounds. It is important to remember that hydrogen is an energy carrier and not an energy source; it must be generated from other primary energy sources (such as wind and solar) converting and storing energy in the form of hydrogen.  

 

 

The ideal scenario is to produce green hydrogen via electrolysis where water (H2O) is split using electricity into hydrogen (H2) and oxygen (O2). This makes green hydrogen potentially completely green and clean if the process uses electricity from renewable sources. The overall chemical reaction is shown below: 

However, the use of water—a critical resource—as a feedstock for green hydrogen, especially in aviation, raises significant ethical concerns. Your customer’s management team is divided on the potential impact of this practice on global water scarcity, which has been exacerbated by climate change. You have been tasked with assessing the feasibility of using green hydrogen in aviation for your client. Your customer has chosen their London to New York route (3,500 nmi), one of their most popular, as a test-case. 

 

 

Despite its potential for green production, globally the majority of hydrogen is currently produced from fossil fuels – termed grey hydrogen. One of your team members has proposed using grey hydrogen as an interim solution to bridge the transition to green hydrogen, in order for the company to start developing the required hydrogen-related infrastructure at airports. They argue that carbon capture and storage technology could be used to reduce carbon emissions from grey hydrogen while still achieving the goal of decarbonisation. Hydrogen from fossil fuels with an additional carbon capture step is known as blue hydrogen. 

However, this suggestion has sparked a heated debate within the management team. While acknowledging the potential to address the immediate concerns of generating enough hydrogen to establish the necessary infrastructure and procedures, many team members argued that it would be a contradictory approach. They highlighted the inherent contradiction of utilising fossil fuels, the primary driver of climate change, to achieve decarbonisation. They emphasised the importance of remaining consistent with the ultimate goal of transitioning away from fossil fuels altogether and reducing overall carbon emissions. Your expertise is now sought to weigh these options and advise the board on the best course of action. 

 

 

Part three: Hydrogen storage 

Despite an impressive gravimetric energy density (the energy stored per unit mass of fuel) hydrogen has the lowest gas density and the second-lowest boiling point of all known chemical fuels. These unique properties pose challenges for storage and transportation, particularly in the constrained spaces of an aircraft.  

 

 

As the lead engineering consultant, you have been tasked with providing expert advice on viable hydrogen storage options for aviation. Your customer has again chosen their London to New York route (3,500 nmi) as a test-case because it is one of their most popular, transatlantic routes. They want to know if hydrogen storage can be effectively managed for this route as it could set a precedent for wider adoption for their other long-haul flights. The plane journey from London to New York is estimated to require around 15,000 kg of hydrogen (or use the quantity estimated previously estimated in Part 2 – see Appendix for example).  

 

 

Part four: Emissions and environmental impact 

In Part four, we delve deeper into the environmental implications of using hydrogen as a fuel in aviation with a focus on emissions and their impacts across the lifecycle of a hydrogen plane. Aircraft can be powered using either direct combustion of hydrogen in gas turbines or by reacting hydrogen in a fuel cell to produce electricity that drives a propeller. As the lead engineering consultant, your customer has asked you to choose between hydrogen combustion in gas turbines or the reaction of hydrogen in fuel cells. The management team is divided on the environmental impacts of both methods, with some emphasising the technological readiness and efficiency of combustion and others advocating for the cleaner process of fuel cell reaction.  

 

 

Both combustion of hydrogen in an engine and reaction of hydrogen in a fuel cell will produce water as a by-product. The management team are concerned over the effect of using hydrogen on the formation of contrails. Contrails are clouds of water vapour produced by aircraft that have a potential contribution to global warming but the extent of their impact is uncertain.  

 

 

So far we have considered each aspect of the hydrogen debate in isolation. However, it is important to consider the overall environmental impact of these stages as a whole. Choices made at each stage of the hydrogen cycle – generation, storage, usage – will collectively impact the overall environmental impact and sustainability of using hydrogen as an aviation fuel and demonstrates how interconnected our decisions can be.  

 

 

Part five: Hydrogen aviation stakeholders 

Hydrogen aviation is an area with multiple stakeholders with conflicting priorities. Understanding the perspectives of these key players is important when considering the feasibility of hydrogen in the aviation sector.   

 

 

Your consultancy firm is hosting a debate for the aviation industry in order to help them make a decision around hydrogen-based technologies. You have invited representatives from consumer groups, the UK government, Environmental NGOs, airlines, and aircraft manufacturers.  

 

 

Stakeholder Key priorities and considerations
Airline & Aerospace Manufacturer 
  • Cost efficiency (fuel, labour, fleet maintenance) – recovering from pandemic. 
  • Passenger experience (commercial & freight). 
  • Develop & maintain global supply chains. 
  • Safety, compliance and operational reliability. 
  • Financial responsibility to employees and investors. 
  • Need government assurances before making big capital investments. 
UK Government 
  • Achieve net zero targets by 2050 
  • Promote economic growth and job creation (still recovering from pandemic). 
  • Fund research and innovation to put their country’s technology ahead. 
  • Fund renewable infrastructure to encourage industry investment. 
Environmental NGOs 
  • Long-term employment for aviation sector. 
  • Demand a sustainable future for aviation to ensure this – right now, not in 50 years. 
  • Standards and targets for industry and government and accountability if not met. 
  • Some NGOs support drastic cuts to flying. 
  • Want to raise public awareness over sustainability of flying. 
Consumer 
  • Environmentally aware (understand the need to reduce carbon emissions). 
  • Also benefit greatly from flying (tourism, commercial shipping, etc.). 
  • Safety and reliability of aircraft & processes. 
  • Cost effectiveness – want affordable service

Appendix: Example calculations 

There are multiple methods for approaching these calculations. The steps shown below are just one example for illustrative purposes.  

 

Part two: Hydrogen production 

Challenge: Estimate the volume of water required for a hydrogen-powered aircraft.   

Assumptions around the hydrogen production process, aircraft, and fuel requirement can be given to students or researched as a separate task. In this example we assume: 

 

Example estimation: 

1. Estimate the energy requirement for a mid-size jet 

No current hydrogen-fuelled aircraft exists, so we can use a kerosene-fuelled analogue. Existing aircraft that meet the requirements include the Boeing 767 or 747. The energy requirement is then: 

 

2. Estimate the hydrogen requirement 

Assuming a hydrogen plane has the same fuel requirement:

 

3. Estimate the volume of water required 

Assuming all hydrogen is produced from the electrolysis of water: 

Electrolysis reaction:

For this reaction, we know one mole of water produces one mole of hydrogen. We need to calculate the moles for 20,000 kg of hydrogen: 

 

 

 

With a 1:1 molar ratio, we can then calculate the mass of water: 

This assumes an electrolyser efficiency of 100%. Typical efficiency values are under 80%, which would yield: 

 

Challenge: Is it feasible to power the UK aviation fleet with water? 

 

The total energy requirement for UK aviation can be given to students or set as a research task.  

Estimation can follow a similar procedure to the above. 

Multiple methods for validating and assessing the feasibility of this quantity of water. For example, the UK daily water consumption is 14 billion litres. The water requirement estimated above is < 1 % of this total daily water consumption, a finding supported by FlyZero.  

 

Part three: Hydrogen storage 

Challenge: Is it feasible to store 20,000 kg of hydrogen in an aircraft? 

There are multiple methods of determining the feasibility of storage volume. As example is given below. 

 

1. Determining the storage volume 

The storage volume is dependent on the storage method used. Density values associated with different storage techniques can be research or given to students (included in Table 2). The storage volume required can be calculated from the mass of hydrogen and density of storage method, example in Table 2.  

Table 2: Energy densities of various hydrogen storage methods 

 

2. Determining available aircraft volume 

A straightforward method is to compare the available volume on an aircraft with the hydrogen storage volume required. Aircraft volumes can be given or researched by students. Examples: 

This assumes hydrogen tanks are integrated into an existing aircraft design. Liquid hydrogen can feasibly fit into an existing design, though actual volume will be larger due to space/constraint requirements and additional infrastructure (pipes, fittings, etc) for the tanks. Tank size can be compared to conventional kerosene tanks and a discussion encouraged over where in the plane hydrogen tanks would need to be (conventional liquid fuel storage is in the wings of aircraft, this is not possible for liquid storage tanks due to their shape and infrastructure storage is inside the fuselage). Another straightforward method for storage feasibility is modelling the hydrogen volume as a simple cylinder and comparing to the dimensions of a suitable aircraft.  

 

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License. 

Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters. 
 
 
To view a plain text version of this resource, click here to download the PDF.

Case enhancement: Developing an internet constellation

Activity: Anatomy of an internet satellite.

Author: Sarah Jayne Hitt, Ph.D. SFHEA (NMITE, Edinburgh Napier University).

 

Overview:

This enhancement is for an activity found in the Dilemma Part two section. It is based on the work done by Kate Crawford and Vladan Joler and published by the SHARE Lab of the SHARE Foundation and the AI Now Institute of New York University, which investigates the “anatomy” of an Amazon Echo device in order to “understand and govern the technical infrastructures” of complex devices. Educators should review the Anatomy of an AI website to see the map and the complementary discussion in order to prepare and to get further ideas. This activity is fundamentally focused on developing systems thinking, a competency viewed as essential in sustainability that also has many ethical implications. Systems thinking is also an AHEP outcome (area 6). The activity could also be given a supply chain emphasis.

This could work as either an in-class activity that would likely take an entire hour or more, or it could be a homework assignment or a combination of the two. It could easily be integrated with technical learning. The activity is presented in parts; educators can choose which parts to use or focus on.

 

1. What are the components needed to make an internet satellite functional?:

First, students can be asked to brainstorm what they think the various components of an internet satellite are without using the internet to help them. This can include electrical, mechanical, and computing parts.

Next, students can be asked to brainstorm what resources are needed for a satellite to be launched into orbit. This could include everything from human resources to rocket fuel to the concrete that paves the launch pad. Each of those resources also has inputs, from chemical processing facilities to electricity generation and so forth.

Next, students can be asked to brainstorm what systems are required to keep the internet satellite operational throughout its time in orbit. This can include systems related to the internet itself, but also things like power and maintenance.

Finally, students can be asked to brainstorm what resources will be needed to manage the satellite’s end of life.

Small groups of students could each be given a whiteboard to make a tether diagram showing how all these components connect, and to try to determine the path dependencies between all of them.

To emphasise ethics explicitly, educators could ask students to imagine where within the tether diagram there could be ethical conflicts or dilemmas and why. Additionally, students could reflect on how changing one part of the system in the satellite would affect other parts of the system.

 

2. How and where are those components made?:

In this portion of the activity, students can research where all the parts of those components and systems come from – including metals, plastics, glass, etc. They should also research how and where the elements making up those parts are made – mines, factories, chemical plants, etc. – and how they are then shipped to where they are assembled and the corresponding inputs/outputs of that process.

Students could make a physical map of the globe to show where the raw materials come from and where they “travel” on their path to becoming a part of the internet satellite system.

To emphasise ethics explicitly, educators could ask students to imagine where within the resources map there could be ethical conflicts or dilemmas and why, and what the sustainability implications are of materials sourcing.

 

3. The anatomy of data:

In this portion of the activity, students can research how the internet provides access to and stores data, and the physical infrastructures required to do so. This includes data centres, fibre optic cables, energy, and human labour. Whereas internet service is often quite localised (for instance, students may be able to see 5G masts or the service vans of their internet service provider), in the case of internet satellites it is very distant and therefore often “invisible”.

To emphasise ethics explicitly, educators could ask students to debate the equity and fairness of spreading the supply and delivery of these systems beyond the area in which they are used. In the case of internet satellites specifically, this includes space and the notion of space as a common resource for all. This relates to other questions and activities presented in the case study.

 

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.

Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.

Theme: Universities’ and business’ shared role in regional development; Collaborating with industry for teaching and learning; Knowledge exchange; Research; Graduate employability and recruitment.

Author: Prof Matt Boyle OBE (Newcastle University).

Keywords: Electrification; Collaboration Skills; Newcastle.

Abstract: Driving the Electric Revolution is led by Newcastle and is a collaborative R&D project to build supply chains in Power Electronics Machines and Drives. The University led the bid and as we amass supply chain capability we will generate £ Billions in GVA.

 

Newcastle University has been embedded in the academic and industrial development of the North East of England since 1834. Recently, one of its core competencies, Machines and Drives research, has been used to attract investment to the region from Industry and Government helping to increase the economic prospects for the North East region.

Newcastle University is the national lead organisation for Driving the Electric Revolution Industrialisation Centres an Industrial Strategy Challenge Fund Wave 3 competition. The centres serve two purposes,

  1. A focal point for development of manufacturing processes in Power Electronics, Machines and Drives (PEMD) through investment in cutting edge manufacturing equipment.
  2. The training of researchers, students, employees of industrial partners on these important new processes.

The Driving the Electric Revolution (DER) Industrialisation Centres (DERIC) project aims to accelerate UK industrialisation of innovative and differentiated PEMD manufacturing and supply chain solutions. They are doing this by creating a national network to coordinate and leverage the capabilities of 35 Research and Technology Organisations (RTO) and academic establishments, based within four main centres.  Supported by 166 industrial partners it represents the largest coordinated industrialisation programme the UK PEMD sector has ever seen.

Newcastle University has, in living memory, always been at the forefront of Electric Machines and Drives innovation globally. It was inevitable that Newcastle would lead the DER project given its pedigree, reputation and the fact that it was supported by several companies in several sectors, Automotive, Aerospace and domestic products who undertake product research in the North East and who seek to manufacture in the UK if possible.

Newcastle did recognise however that it couldn’t deliver the government programme alone. There were four institutions which formed a consortium to bid into the competition, Newcastle University, University of Strathclyde, Warwick Manufacturing Group and the Compound Semiconductor Applications Catapult in Newport South Wales. Over time they have been joined by University of Nottingham, University of Birmingham, Swansea University and University of Warwick. Letters of support were received from 166 Industry partners, 27 FE and HE organisations expressed support as did 13 RTOs. Although the national bid was led by Newcastle, it took a more North East regional view in development of its delivery model.

Therefore, in addition to this national work, Newcastle extended their DERIC application beyond Newcastle to Sunderland where they worked with Sunderland council to establish a DERIC research facility in the area. Sunderland city council worked with Newcastle to acquire, fit out and commission the lab which received equipment from the project and is due to open in 2022.

Nationally the primary outcome is the establishment of the Driving the Electric Revolution Industrialisation Centres and the network.

The four DERIC act as focal points for the promotion of UK PEMD capabilities. They design develop and co-sponsor activities at international events. They send industrial representatives to meet with clients and research partners from UK, Europe and Asia, as well as developing a new UK event to attract leading PEMD organisations from around the globe.

In Newcastle the university’s sponsorship of both the national project as well as the DERIC in the North East is helping attract, retain and develop local innovation and investment. The equipment granted by the DER Challenge to the centre includes a Drives assembly line as well as an advanced Machines line. The DERIC is focused primarily in the development of manufacturing processes using the granted equipment. The equipment was selected specifically with these new processes in mind. The success of the DERIC program already means that the country and the region have attracted substantial inward investment.

Investments by three companies came to the North East because of the capability developed in the region. They have all agreed partnerships with the university in the process of establishing, acquiring and investing in the North East. The three companies are:

  1. British Volt mission is to accelerate the electrification of society. They make battery cells. Their Gigaplant in Northumberland will be the second Gigaplant in the UK. They are investing £1Bn into the region creating around 5,000 jobs both at the plant and in the supply chain.
  2. Envision also make batteries. Unlike British volt the Envision cell is a Gel pack. Envision has the first Gigaplant in the UK at Sunderland. They are investing a further £450M to expand the plant in Sunderland and potentially another £1.8Bn by 2030.
  3. Turntide Technologies invested £110M into the region acquiring three businesses. These have all in some fashion been supported by and supportive of the PEMD capability at Newcastle over the past six decades.

The university has worked tirelessly to help create an ecosystem in the region for decarbonisation and electrification.

The last stage of this specific activity is the creation of the trained employees for this new North East future. The university, collaborating across the country with DER partners, is embarking on an ambitious plan to help educate, train and upskill the engineers, scientists and operators to support these developments. It is doing this by collaborating, for the North East requirement, with the other universities and further education colleges in the region. Industry is getting involved by delivering a demand signal for its requirements. The education, training and up skilling of thousands of people over the next few years will require substantial investments by both the educators in the region as well as industry.

As the pace of electrification of common internally combusted applications accelerates the need for innovation in the three main components of electrification, power source, drive and machine will grow substantially. The country needs more electrification expertise. The North East region has many of the basic building blocks for a successful future in electrification. Newcastle University and its Academic and Industrial partners have shown the way ahead by collaborating, leading to substantial inward investment which will inevitably lead to greater economic prosperity for the region. Further information is available from the Driving the Electric Revolution Industrialisation Centres website. In addition, there are annual reports and many events hosted, sponsored or attended by the centres.

Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.

Theme: Collaborating with industry for teaching and learning

Authors: Prof Lucy Rogers (RAEng Visiting Professor at Brunel University, London and freelance engineering consultant) and Petra Gratton (Associate Dean of Professional Development and Graduate Outcomes in the College of Engineering, Design and Physical Science at Brunel University London, and Lecturer in the Department of Mechanical and Aerospace Engineering)

Keywords: Industry, Interview, Video, Real Life, Engineers

Abstract: A number of short videos that can be re-used in teaching undergraduate modules in Engineering Business, instead of inviting guest presentations. The interview technique got each individual to talk about their life experiences and topics in engineering business that are often considered mundane (or challenging) for engineers, such as ethics, risks and regulation, project management, innovation, intellectual property, life-cycle assessment, finance and creativity. They also drew attention to their professional development.

 

Project outcomes

The outcomes of this project are a number of short videos that were used, and can be re-used, in teaching delivery of an undergraduate module in Engineering Business in the Department of Mechanical and Aerospace Engineering at Brunel University London instead of having guest presentations from invited speakers.  Lucy’s interview technique got the individuals featured in each film to talk about their life experiences and topics in engineering business that are often considered mundane (or challenging) for engineers, such as ethics, risks and regulation, project management, innovation, intellectual property, life-cycle assessment and finance; and drew attention to their professional development. 

The shorter videos were inspirational for students to make videos of themselves as part of the assessment of the module, which required them to carry out a personal professional reflection exercise and report upon what they had learned from the exercise in a simple 90-second video using their smartphone or laptop. 

Having used the videos with Brunel students, Lucy has made them available on her YouTube channel: Dr Lucy Rogers – YouTube. Each of the videos are listed in the following table:

 

Topic Who Video Link
Creativity in Engineering: Your CV Reid Derby https://youtu.be/qQILO4uXJ24
Creativity in Engineering: Your CV Leigh-Ann Russell https://youtu.be/LJLG2SH0CwM
Creativity in Engineering: Your CV Richard Hopkins https://youtu.be/tLQ7lZ3nlvg
Corporate Social Responsibility Alexandra Knight
(Amey Strategic Consulting)		 https://youtu.be/N7ojL6id_BI
Ethics and Diversity Alexandra Knight
(Amey Strategic Consulting)		 https://youtu.be/Q4MhkLQqWuI
Project Management and Engineers Fiona Neads (Rolls Royce) https://youtu.be/-TZlwk6HuUI
Project Management – Life Cycle Paul Kahn
(Aerospace and Defence Industry)		 https://youtu.be/1Z4ZXMLRPt4
Ethics at Work Emily Harford (UKAEA) https://youtu.be/gmBq9FIX6ek
Communication Skills at Work Emily Harford (UKAEA) https://youtu.be/kmgAlyz7OhI
Client Brief Andy Stanford-Clark (IBM) https://youtu.be/WNYhDA317wE
Intellectual Property from Artist’s Point of View Dave Corney
(Artist and Designer)		 https://youtu.be/t4pLkletXIs
Intellectual Property Andy Stanford-Clark (IBM) https://youtu.be/L5bO0IdxKyI
Project Management Fiona Neads – Rolls Royce https://youtu.be/XzgS5SJhiA0

 

Lessons learned and reflections

We learned that students generally engaged with the videos that were used.  Depending which virtual learning environment (VLE) was being used, using pre-recorded videos in synchronous online lectures presents various challenges.  To avoid any unplanned glitches, in future we know to use the pre-recorded videos as part of the teaching-delivery preparation (e.g. in a flipped classroom mode). 

As part of her legacy, Lucy is going to prepare a set of simple instructions on producing video interviews that can be carried out by both staff and students in future.

 

Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.

Theme: Research, Knowledge exchange

Authors: Dr Matteo Ceriotti (University of Glasgow), Niven Payne (Fujitsu UK), Giulia Viavattene (University of Glasgow), Ellen Devereux (Fujitsu UK), Dr David Snelling (Fujitsu UK) and Matthew Nuckley (Fujitsu UK)

Keywords: Space, Debris Removal, Sustainability, Optimisation

Abstract: A partnership between the University of Glasgow, Fujitsu UK, Astroscale and Amazon Web Services was established in response to a UK Space Agency call on Active Debris Removal mission design. This is the process of de-orbiting space debris objects from low Earth orbit with a dedicated spacecraft. The consortium brought together different but complementary expertise and tools to develop an algorithm (using machine learning and quantum-based computing) to design multiple-debris removal missions, able to select feasible sequences of debris objects among millions of permutations, in a fraction of the time of previous methods, and of better performance in terms of time and propellant required.

 

Overview

Space and its services have become part of everyone’s daily life, quietly. Things like mapping, geolocation, telecommunication services and weather forecast all depend on space assets. The continuous and increasing exploration and exploitation of space heavily depends on sustainability: defunct satellites and other spacecraft and launcher parts that became part of space debris population, or “junk”, increasing the threat of collision for current and future missions. There are 34,000 objects larger than 10 cm, and 130 million smaller than 1 cm, including non-operational satellites, upper stage rocket bodies, satellite parts, etc. Most of these objects are in the low Earth orbit region (below 1000 km), which is where most satellites operate.

Design of new satellites for demise prevents the creation of further debris. Active debris removal (ADR) aims dispose of debris objects that are currently in orbit. ADR actions require a “chaser” spacecraft to grapple a “non-cooperative” target, and transfer it to an orbit low enough that it will eventually de-orbit and burn in the atmosphere in a relatively short amount of time.

The idea

Many ADR missions would be required to make a substantial contribution in diminishing the debris population. The business challenge was to investigate how we could make space debris removal missions more commercially viable. This project investigated the feasibility, viability and design of removal and disposal of multiple debris objects using a single chaser spacecraft. The mission scenario involves a spacecraft that transfers to the orbit of one or more objects, captures it (or them), and then transfers to a lower orbit for release and disposal. At low altitude, the atmospheric drag will quickly cause the object to rapidly fall and burn in the atmosphere. In the meantime, the chaser spacecraft will transfer to another object (or set of objects) and continue the mission.

 

The problem

With million pieces of space junk, there are multiple trillions of permutations for ADR missions between these objects, that would need to be investigated, to efficiently remove even only a few of them. Since orbital transfers have no analytical closed-form solutions, an optimisation strategy must be used to find a solution to trajectory design problems, which is generally computationally demanding.

Our solution

The aim of this project was to make space debris removal missions more commercially viable, through a new solution that allows fast mission planning. First, an Artificial Neural Network (ANN) is trained to predict the cost of orbital transfer to and disposal of a range of debris objects quickly. Then, this information is used to plan a mission of four captures from candidate possible debris targets using Fujitsu’s quantum-inspired optimisation technology, called Digital Annealer (DA), by formulating the problem as a quadratic unconstrained binary optimisation. We used Astroscale’s mission planning data and expertise, and run the algorithms on the Amazon Web Services (AWS) Sagemaker platform. For technical details on our approach, the reader is referred to the publications below.

Outcomes

In a test-scenario, we showed that our solution produced a 25% faster mission, using 18% less propellant when compared to an expert’s attempt to plan the mission using the same assumptions; this was found 170,000 times faster than current methods based on an expert’s work.

Partnership

The project involved the partnership of four institutions, with areas of contributions described in the following diagram:

We believe the key to the success of the partnership was the different, but complementary areas of expertise, tools offered, and contribution of each partner into the project. It may be easier to rely on existing network of contacts, often with similar areas of expertise. However, this project shows that the additional effort of creating a new partnership can have great benefits, that overcome the initial difficulties.

Project set up

An initial contact between Fujitsu and UofG defined the original idea of the project, combining the existing expertise on discrete optimisation (Fujitsu) and multi-body space missions (UofG). The team was strengthened by expertise in active space debris removal (Astroscale) and cloud computing (AWS). The project proposal was funded by the United Kingdom Space Agency (UKSA), for a duration of four months, from September 2020 to January 2021.

Due to the on-going global pandemic, the project was run entirely online, with weekly meetings on Microsoft Teams. Fujitsu, as team lead, was responsible for planning and scheduling of tasks, as well as integration of code and reporting.

Lessons learned and reflections

Reactivity in preparing a project proposal was fundamental for the project: The very first contact between the partners was made at the end of July 2020, the proposal was submitted in mid-August and the project officially kicked-off in September.

Given the short timeframe, it was important to conceive a project proposal that fit the scope of the funder, but also matches with available expertise and personnel. It was also critical to frame the business challenge in the proposal.

From the point of view of the academic team, and again given the short window between notification of successful application and start of the project, these factors were crucial for the success of the project:

A PhD student in the research group was the best candidate for the project: at the cost of taking a leave-of-absence from the PhD studentship, the project constituted a unique experience with industrial collaboration, enriched their CV through a ground-breaking project, added a conference and a journal paper to their track record, and eventually opened new areas of investigation for the rest of the PhD studentship.

It would have been probably unthinkable – or at not very credible – to deliver a project with new partners remotely without any in-person meeting before the pandemic; however, this turned out to be an enabler for this project, allowing to maximise time on actual development and save on travel costs.

Further information

G. Viavattene, E. Devereux, D. Snelling, N. Payne, S. Wokes, M. Ceriotti, Design of multiple space debris removal missions using machine learning, Acta Astronautica, 193 (2022) 277-286. DOI: 10.1016/j.actaastro.2021.12.051

D. Snelling, E. Devereux, N. Payne, M. Nuckley, G. Viavattene, M. Ceriotti, S. Wokes, G. Di Mauro, H. Brettle, Innovation in planning space debris removal missions using artificial intelligence and quantum-inspired computing, 8th European Conference on Space Debris, ESA/ESOC, Darmstadt, Germany (Virtual Conference), 2021.

 

Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.

Authors:  Dr Nik Whitehead (University of Wales Trinity Saint David); Dr Sarah Jayne Hitt SFHEA (NMITE); Professor Thomas Lennerfors (Uppsala University); Claire Donovan (Royal Academy of Engineering); Professor Raffaella Ocone OBE FREng FRSE (Heriot Watt University); Isobel Grimley (Engineering Professors’ Council).

Topic: Low earth orbit satellites for internet provision. 

Engineering disciplines: Electronics, Mechanical engineering.

Ethical issues: Respect for environment, Public good, Future generations.

Professional situations: Communication, Management, Working cultures.

Educational level: Intermediate.

Educational aim: Practise ethical analysis. Ethical analysis is a process by which ethical issues are defined, affected parties and consequences are identified, so that relevant moral principles can be applied to a situation in order to determine possible courses of action. 

 

Learning and teaching notes:

This case is about an experienced engineer leading a team at a tech start-up. The company has been awarded a contract to produce an innovative satellite that will be used in an internet constellation. While the team was initially excited about their work, some members are now concerned about the impact of the internet constellation. While mainly focused on environmental ethics, effects on human communities are also raised in this case study.

This case study addresses two of AHEP 4’s themes: The Engineer and Society (acknowledging that engineering activity can have a significant societal impact) and Engineering Practice (the practical application of engineering concepts, tools and professional skills). To map this case study to AHEP outcomes specific to a programme under these themes, access AHEP 4 here and navigate to pages 30-31 and 35-37.

The dilemma in this case is presented in two parts. If desired, a teacher can use Part one in isolation, this section enables students to practise different types of analysis and to introduce aspects of environmental ethics. It highlights the challenges of making ethical decisions with global consequences, in scenarios where policy isn’t clear. Part two develops and complicates the concepts presented in Part one to provide for additional learning by focusing on the course of actions taken by an individual engineer based on the dilemma presented in Part one. The Challenge of Environmental Ethics linked below is recommended, though not required, for students engaging with this case. Additionally, throughout the case, there is the option to stop at multiple points for questions and / or activities as desired.

Learners have the opportunity to:

Teachers have the opportunity to:

 

Learning and teaching resources: 

 

Summary: 

After years of working your way up the corporate ladder, you are now Head of Engineering for a tech start-up. The company has won a contract connected to a project creating a constellation of thousands of low Earth orbit satellites. This constellation has the potential to create a reliable system of internet access for areas of the world that are hard to reach by conventional infrastructure. Your company is one of those chosen to develop and build a low-cost, lightweight, efficient satellite that can be produced at scale. This is a huge accomplishment for you, as well as for your company. 

 

Dilemma – Part one:

A conference that brings together various project partners is met by protesters whose message is that the internet constellation has several potential negative impacts for nature and human communities. Disparaging comments have been made about your company’s participation in the project on social media. Some members of your team seem quite rattled by the protests, and you convene at a coffee shop to discuss. 

 

Optional STOP for questions and activities:

1. Discussion: Technical analysis – Undertake a technical activity in the areas of electronic and / or mechanical engineering related to internet constellations.

2. Activity: Position analysis – Divide students into three groups—constellation project managers; satellite engineers and protestors. Imagine how their positions are related to the internet constellation. What values might inform their positions? What knowledge might inform their position that the other groups do not have access to or understanding of?

3. Discussion: Environmental analysis – While nature cannot speak for itself, if it could, what might be its position on the internet constellation? What aspects of the natural world might be affected by this technology in both the short- and long-term? For example, are there any direct or indirect effects on the health of humans and the ecosystems around them? Should the natural world of space be treated the same way as the natural world on earth?

4. Discussion: Policy analysis – Who should make decisions about projects that affect nature on a global scale? What laws or regulations exist that govern internet constellations?

5. Discussion and Activity: Moral analysis – Use environmental ethics principles such as intrinsic value and anthropocentrism to debate the project. Beyond environmental concerns, how might other ethical approaches, such as consequentialism or justice, inform positions on the issue?

 

Dilemma – Part two:

You remind and explain to your team members that they, and the company, have a duty to the client. Everyone has been hired to deliver a specific project and been excited about overcoming the technical challenges to ensure the project’s success. The team agrees, but also expresses concern about aspects that aren’t in the project remit, such as how the satellite will be maintained and what will happen to it at the end of its life. They demand that you pause your work until an ethical review is conducted. 

You report all of this to the CEO, who reacts with disappointment and unhappiness at your team’s actions. She argues that the only thing your company is doing is building the satellite: it’s not your responsibility what happens to it afterwards. She feels that it’s your job to get your team back in line and on task. How do you approach this situation? 

 

Optional STOP for questions and activities:

1. Discussion and Activity: How do you respond to this situation? What responsibilities do you have to your team, your boss, and the client? How will you balance these? Are the team’s engineers right to be concerned about the impact of their satellite within the wider constellation, or is it beyond their scope? Role-play an interaction between you and the engineering team, or between you and your boss.

2. Activity: Life cycle analysis – Research life cycles of satellites and their environmental impact.

3. Discussion and Activity: Debate if, and how, we have obligations to future generations. Is it possible to have a moral contract with a person that may never be born? How do we know that people in the future, will value the same things we do now? Both creating the internet constellation and preventing its implementation seem to potentially benefit future generations. How do we balance these ‘goods’ and make a decision on how to proceed? Who gets to decide?

4. Activity: Anatomy of an internet satellite – use the Anatomy of an AI case study as an example of a tether map, showing the inputs and outputs of a device. Create a tether map showing the anatomy of an internet satellite.

 

Enhancements:

An enhancement for this case study can be found here.

 

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.

Any views, thoughts, and opinions expressed herein are solely that of the author(s) and do not necessarily reflect the views, opinions, policies, or position of the Engineering Professors’ Council or the Toolkit sponsors and supporters.

 

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