KTP to tackle one of automotive’s biggest sustainability issues

Left to right: Peter Douglas, general manager (commercial) at Metal Assemblies and Ronnie Akumu, KTP partner

In a UK-first for the automotive supply chain, Aston Business School is teaming up with West Bromwich manufacturer Metal Assemblies to calculate and report the carbon cost of every metal component used in car production, tackling one of the industry’s biggest sustainability challenges. It is hoped the Knowledge Transfer Partnership (KTP) will transform how vehicle parts are made and regulated, setting a new standard for transparency and low-carbon manufacturing across Europe. Metal Assemblies produces a wide range of machined metal components and welded assemblies, supplying Toyota, BMW and Nissan, among other manufacturers in the UK and Europe.

New environmental regulations, such as the European Union (EU) Carbon Border Adjustment Mechanism, now require detailed data on the carbon cost of each vehicle component and place tariffs on carbon intensive goods. Developing more sustainable approaches to manufacture vehicle parts will help the sector to limit these tariffs and support efforts to decarbonise the automotive industry.

Through a three-year KTP with Aston University, Metal Assemblies is gaining access to specialist data and operations expertise. The project will design and integrate an innovative approach to energy efficiency across the company’s entire manufacturing process. This will deliver a competitive edge into the business, supercharging its plans to be the first in the sector to offer detailed carbon cost information.

Product life-cycle analysis
The project will collect and analyse data on energy consumption at Metal Assemblies based on a product life-cycle analysis and will create a sustainable manufacturing strategy for the company. This will allow it to better market different products and processes based on their carbon content and possible trade-offs.

The team will also use a concept called ‘Sustainability Fitness’, developed by Aston University academics, to measure how healthy and sustainable the company is. Using this approach, the project team expects to identify the most urgent and cost-effective improvements while also making sure the company stays competitive and meets regulations.

By enabling Metal Assemblies to work in partnership with customers to design more sustainable components, this KTP will support the wider sector to adopt alternative, lower-impact manufacturing techniques. The project builds on a previous digital transformation KTP between the two partners to design and embed automated Industry 4.0 manufacturing processes across Metal Assemblies.

Iain Collis, CEO of Metal Assemblies, said: “There isn’t yet a structured, robust approach in the automotive supply chain for measuring the carbon cost of components and reporting this up the chain to customers. By working with Aston Business School to develop a systematic method for assessing environmental impact, we will be transforming this end of the supply chain in ways that provide value to our customers while differentiating ourselves from our competitors.”

Clear direction
Dr Breno Nunes, reader in sustainability operations management at Aston Business School, said: “Through the Corporate Sustainability Fitness Model, we will be providing Metal Assemblies with a visual dashboard that clearly shows the company’s sustainability performance, trade-offs of each potential shift in their strategy, and a clear direction to take for a more sustainable future. This offers a new way to think about sustainability – one that balances short-term economic needs and longer-term sustainability requirements.”

Aston Business School offers the advanced research capabilities and specialist knowledge required to transform manufacturing processes at Metal Assemblies so they are fit for a ‘greener’ future. Its team bring a wealth of expertise in data security, data analysis, and performance and impact measurement into the business, as well as a track record in supporting organisations to formulate, implement and measure sustainability. It is one of the UK’s leading business schools, ranking in the UK’s top 10 and 66th in the 2024 QS World University Rankings by subject for Business and Management Studies.

KTPs, funded by Innovate UK, are collaborations between a business, a university and a highly qualified research associate. The UK-wide programme helps businesses to improve their competitiveness and productivity through the better use of knowledge, technology and skills. Aston University is a sector-leading KTP provider, ranked first for project quality, and joint first for the volume of active projects.