Comment: Open automation can close the skills gap

Skills shortages remain a major challenge for UK manufacturers, with 75 per cent citing them as a barrier to growth, according to Barclays Corporate Banking. However, this issue runs deeper than recruitment as only 20 per cent of engineering graduates enter manufacturing, revealing a disconnect between academic training and industry needs.

Those engineering graduates that do enter the workforce often do so with strong theoretical knowledge but little hands-on experience with the technologies that drive modern manufacturing. Traditional university curricula often emphasise coding and mechatronics but may lack direct exposure to the industrial systems in use today, creating a gap between academic training and the technical expertise employers need.

A major contributor to this divide is the reliance on proprietary automation platforms. Many industrial control systems operate within closed ecosystems that require specialised knowledge, making it difficult for new engineers to transition smoothly from academia to industry.

As a result, vendor specific training is often required, creating barriers to entry. At a time when the industry faces labour shortages, companies must rethink their approach.

Open standards

Enter open standards, which provide a clear path forward by encouraging interoperability between different systems. Technologies like Open Platform Communications Unified Architecture (OPC UA) and Ethernet for Control Automation Technology (EtherCAT) break down the silos created by proprietary solutions, allowing engineers to work across different systems without starting from scratch.

By embracing open standards, companies enable graduates to apply their existing programming skills, often in languages like Python, C++ and structured text, rather than requiring them to learn rigid, vendor-specific languages. This not only accelerates the onboarding process but also encourages innovation, as engineers can focus on solving problems rather than navigating proprietary constraints.

The effects of this change could be huge. As the industry moves toward greater interoperability and software-driven automation, graduates will no longer need to be confined to specific vendors or legacy systems. They can develop expertise that is transferable across industries, making them more valuable to employers and accelerating digital transformation.

In practice

The challenge for companies today is how quickly they will embrace open standards, like OPC UA and EtherCAT. These are crucial in modern industrial automation, because they enhance interoperability and flexibility, allowing graduates to apply their coding skills across diverse systems without being limited to a single vendor's ecosystem.

OPC UA is a platform-independent, service-oriented architecture that ensures secure and reliable data exchange across various industrial devices and systems. Its scalability and adaptability also make it a preferred choice for integrating different automation components. In fact, the OPC Foundation has reported a nine per cent compound annual growth rate in its membership over the past five years.

EtherCAT, on the other hand, is a high-performance Ethernet-based fieldbus system designed for real-time industrial communication. Its "on-the-fly" processing method allows for efficient data exchange, making it particularly well-suited for applications requiring precise timing and synchronisation.

What’s more, EtherCAT’s real-time capabilities are achieved without additional hardware, using standard Ethernet ports on industrial PCs. This reduces costs and enhances system openness, minimising dependency on specific hardware manufacturers.

OpenCV & getting into industry

OpenCV, an open-source computer vision library, plays a crucial role in bridging the gap between academic learning and industrial applications, especially in automation and robotics. Widely adopted in academia, OpenCV equips students with practical skills in image and video processing, which are directly applicable to industrial scenarios.

By incorporating OpenCV into industrial processes, companies can use the fresh perspectives of new graduates while developing a culture of innovation and continuous improvement. This integration not only eases the transition from academia to industry but also enhances organisational adaptability in an industry accustomed to change.

Transitioning from academic studies to professional roles in industrial automation can be challenging for graduates. When applying for roles in industrial automation, showcasing hands-on experience can be just as important as listing academic achievements.

Employers are increasingly looking for candidates who can demonstrate practical skills with real-world applications, not just theoretical knowledge. One way to stand out in interviews is by presenting personal projects that highlight your ability to work with automation technologies outside of a structured work environment.

For example, if asked to demonstrate your experience with automation software, having a functional project built using industry-standard tools can set you apart. Instead of simply discussing coursework or simulations, bringing a project you’ve developed independently can showcase initiative, problem-solving skills and familiarity with industrial technologies.

To support this, Beckhoff offers free access to its TwinCAT 3 software suite, allowing users to develop automation applications without costly licensing barriers. This provides an accessible platform for students and engineers to apply their skills in automation.

Although the skills gap in UK manufacturing is a significant challenge, embracing open automation technologies offers a way forward. By promoting open standards like OPC UA and EtherCAT, along with providing hands-on development platforms, companies and educational institutions can better prepare the next generation of engineers.

With digital transformation underway, now is the time to act — both to address the skills gap and help future engineers to not only join the industry but stay in it too.

Adam Carless, vision product specialist at Beckhoff UK