PES Media Production Engineering Solutions ukmfgnews July 2024 pesmedia.com Kasto: pioneering automation, storage and sawing solutions since 1844 Pages 20-22 180 years of industrial innovation Laser Profiling: pages 34-35 Machined Components: pages 36-38 SUBCONTRACTING SOLUTIONS
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www.pesmedia.com Production Engineering Solutions July 2024 3 Our cover story this month is all about sawing, storage and automation specialist Kasto. I’ve been to their headquarters in Achern, Germany a number of times over the years, but this visit, apart from providing an opportunity to take in all the new technology, also marked a rather important anniversary – 180 years since the company’s formation. It got me thinking about how companies like Kasto are able to survive, and indeed thrive, over such a long period of time and I think there’s definitely something to be said for family run businesses. It’s certainly not the only factor in the longevity equation, but it does carry some weight. I’ve visited many family-run subcontract businesses here in the UK and the desire to pass knowledge, skills and family values down through generations is pretty common – and proven. In terms of staff, running a business is all about getting the blend between experience and youthful exuberance right – and it’s a fine line. As an 18-year-old apprentice way back in the murky depths of time, I remember benefitting incredibly from the older guys I worked with. I also remember marvelling at their knowledge and expertise but of course that can only be obtained through years and often decades of experience. Going back to that blend between youth and experience – manufacturing has changed beyond recognition in recent years and the challenge today is attracting new blood into a career in manufacturing and engineering as more seasoned employees retire. I visited tooling company Ceratizit in Austria and Germany earlier this year and they emphasised just how important it is to try and attract young people into the company. It’s the same story with Kasto. Kasto is one of the oldest family run businesses in Europe. Karl Stolzer launched the company back in 1844 and today family values are as strong as ever with fifth and sixth generation family members steering the ship. Karl’s greatgreat-grandson Armin is at the helm after more than 30 years with the business and Armin’s wife Ruth and all four members of the sixth family generation all hold central positions in the company’s executive management structure. For companies like Kasto, family is clearly an important ingredient in the company’s success over an incredible 18 decades – but all that means nothing without relentless product development, continuous innovation and working hard to establish long fruitful partnerships with customers and suppliers. Under Armin Stolzer’s watch, Kasto has excelled on all fronts with more than 140,000 sawing machines sold and over 2,400 storage systems installed. Take a look at my article on pages 20-21. Dave Tudor Editorial Director It’s always inspiring to hear about manufacturing companies celebrating anniversary milestones. The key to longevity of course is a relentless drive to innovate, adapting to ever changing market conditions and continuous investment in staff and infrastructure. 2024 represents a huge landmark for German sawing, storage and automation specialist Kasto as it celebrates 180 years in business. Dave Tudor reports. See pages 20-23 Cover story COMMENT/CONTENTS Production Engineering Solutions is published 12 times per year and is distributed free of charge to applicants in the UK meeting the publisher’s criteria. Subscriptions are also available at £80 per annum to UK readers or £148 overseas. Whilst every care is taken to provide accurate information, the publishers cannot accept liability for errors or omissions, no matter how they may arise. Authors’ opinions do not necessarily reflect those of the publisher. All rights reserved. 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Circulation Statement Published by: MIT Publishing Limited, Featherstone House, 375 High Street, Rochester, Kent ME1 1DA Tel: 01634 830566 Volume 28 Issue 339 ISSN 1460-3926 EVENTS September 2024 UK Metals Expo NEC, Birmingham, UK 11-12 September 2024 October 2024 Advanced Engineering NEC, Birmingham, UK 30-31 October 2024 October 2024 Machine Building Live National Motorcycle Museum, Birmingham, UK 2 October 2024 July 2024 Farnborough International Airshow Farnborough, UK 22-26 July 2024 5 Leicester laser cutting firm secures triple ISO accreditation Laser focus from ETG NEWS MACHINING CENTRES 18 Travelling column machine from DMG Mori is big news Latest Victor HMC offers performance improvements MACHINING 16 New machine tool company hits the ground running SAWING TECHNOLOGY 20 180 years of industrial innovation New circular sawing line for steel distribution EDM 25 Neptune breaks the mould with Sodick TOOLING & WORKHOLDING 27 Fast and stable back working tool holders from Arno New tool for milling drive shaft splines 29 New robotic systems for automating machine tools The fine road ahead for Amada Automation SOFTWARE IN MANUFACTURING 32 Lantek Expert and iQuoting: indispensable at A13 Engineering Precision benefits from insightful MRP Circulation Adept Data Services Ltd T: +44 (0) 800 634 3118 [email protected] Publisher David Rose Editorial Director Dave Tudor T: 01634 825702 [email protected] Deputy Editor Ed Hill T: 01634 825705 [email protected] Production Coordinator Ewa Hodden T: 01634 825703 ehodden@mitpublishing. co.uk Digital Content Coordinator Michael Tyrrell mtyrrell@mitpublishing. co.uk Financial Controller Valerie Prentice [email protected] Sales Manager Tammy Jukes T: 01634 825706 [email protected] Sales Director Andy Morley T: 01634 825701 [email protected] Contacts AUTOMATION & ROBOTICS
TURNING CENTRES 5 AXIS DOUBLE COLUMN SUPERIOR CONTROLS MACHINING CENTRES 12 Merlin Centre • Lancaster Road • Cressex Business Park High Wycombe • Buckinghamshire • HP12 3TB • Tel: (01494) 442222 www.hurco.co.uk, [email protected], [email protected] Your partner for 5 axis machining Several configurations to suit your application Transform plane feature for 5-sided programming Simultaneous 5 axis is standard on all Hurco 5 axis machines SRTi Range • Features a swivel B axis and a rotary C axis set in the table • Maximum 5 axis capacity within a minimum footprint • Can also be used as a full-capacity 3 axis machine • Machines available ex stock VCi/VCXi Range • Cantilever design allows excellent access • Ideal for one-offs • Greater Z clearance • Entry-level and high performance models available Ui Range • Most economical 5 axis configuration • 3 model sizes and several spindle options • Easy to automate with ProCobot or Erowa options • Machines available ex stock DCX-5Si Range • For the BIGGEST of 5 axis jobs • Machines up to 4.2m in X and 2.6m travel in Y • High-speed or High-torque spindle options available • Massive rigid structure for improved accuracy
pesmedia.com Production Engineering Solutions July 2024 5 NEWS COMPANY FINDER 123Insight 33 A13 Engineering 32 ADS Laser Cutting 5 Alloy Wire 10 Amada 30 Arno 27 Axe & Status 34 Behringer 23 Bowers Group 9 BTMA 36 Citizen Machinery UK 14 CMZ 10 CTN Group 36 DMG Mori 18 Engineering Technology Group 5 Express Engineering 6 Forterro 14 GM CNC 18 Group Rhodes 12 Horn Cutting Tools 27 In-Comm Training 13 Kasto 20 Kellys Welding 34 Lantek 32 MRPeasy 9 Neptune Injection 25 Open Mind Technologies 8 Sodi-Tech EDM 25 Syil UK 16 Tooling Intelligence 10 Whitehouse Machine Tools 29 Yamawa 27 Yamazaki Mazak 6 EDITORIAL ADVERTISING 1st Machine Tool Accessories 11 Allied Machine & Engineering 28 Amada 29 Axe & Status 35 Behringer 22 Ceratizit UK & Ireland 40 CNC Repair 8 Effective CNC Solutions 6 Haas 9 Hurco 4 Iscar 26 Kerf Developments 34 Lang Technik 31 MIE Solutions 33 Mills CNC 7, 15 Mini Gears 17 Mitutoyo 12 Muffett Engineering Solutions 17 Nuclear AMRC 13 PSL Datatrack 32 Qualiurn Products 36 Sodi-Tech EDM 24 Subcon Drilling 38 Swissmatic 37 Sykes Machines 23 Tesa 5 Unison 14 Ward Hi-Tech 19 XYZ Machine Tools 2 NEWS Precision Measurement Solutions [email protected] Now available from the Engineering Technology Group (ETG) is the new Durma HD-FO laser cutting machine. As the latest addition to ETG’s Fabrication Division, the new HD-FO series demonstrates high productivity, excellent cut quality and integrated automation solutions that make this new arrival an appealing prospect for sheetmetal manufacturers. The machine, renowned for its manufacturing and energy efficiency, industrial design and ease of use and low operational costs features an ergonomic quick-opening top cover and easy access to the cutting area. The Durma HD-FO laser is a user-friendly machine that integrates automated work processes for greater efficiency. Advanced Durma technology ensures this machine has low running costs in a compact work area. The design minimises the footprint of the Durma HD-FO by incorporating the laser source and chiller inside the machine. Complementing this is the quick-opening front door that has been designed especially for customers with factory layout and space availability issues. Sheet loading and unloading is simple. While a manual cutting table is supplied as standard, customers can optionally select a pneumatic shuttle table option. From a specification perspective, the Durma HD-FO laser has a working area of 3,048 x 1,530 x 125mm in the X-, Y- and Z-axes with a maximum sheet capacity of 575kg. The Durma machine offers X-, Y- and Z-axis travels of 90m/minute and synchronised acceleration of 14m/s² with positional accuracy and repeatability of 0.05mm. The Bosch Rexroth CNC control system and the user-friendly 19inch screen combine to simplify and enhance programming and setting up. The Durma Precitec Lightcutter laser head presents a combination of power and precision that enhances cut quality and edge finishes with its automatic focus that further enhances ease of use. This durable and powerful laser source is available with a range of options that include the YLR1000, YLS2000, YLR3000 and the YLS4000 which offer power from 1 to 4kW for cutting mild steel up to 20mm thick as well as stainless, aluminium, copper, brass and a host of other material types. n Engineering Technology Group www.engtechgroup.com Laser focus from ETG Leicester laser cutting firm secures triple ISO accreditation Ant Littlejohns, compliance manager at ADS Leicester-based metalwork firm, ADS Laser Cutting is celebrating a triple achievement of ISO accreditations covering environmental, health and safety, and quality. At the same time, the firm has also renewed its BS EN 1090 certifications, reinforcing its commitment to quality and compliance in welding and fabrication. Following a recent audit and inspection, ADS has for the first time secured ISO 14001 which provides assurance of its long-term commitment to improvements that reduce its carbon footprint. Another first for the team is its success in obtaining ISO 45001. This focuses on its commitment to improving health and safety in the workplace for the benefit of all employees so they have both a safe and enjoyable environment in which to work. Rounding up these successes, ADS renewed its ISO 9001 quality certification, assuring clients of first-class service across all areas of its business. Commenting on the ISO certifications, Ant Littlejohns, compliance manager at ADS, said: “Receiving these accreditations is a point of great pride, not just for myself but for the whole ADS Laser team, as it is truly a team effort. “Success in these areas requires a tangible demonstration that every employee is both aware of their responsibilities and actively carrying them out in their dayto-day routines. This means our clients can be assured of a market-leading experience, no matter who they’re liaising with. ADS strives to continually improve its processes and practices and deliver a great service for all its stakeholders.” The renewal of ADS’ BS EN 1090 certification demonstrates that all its fabrication work meets European quality and compliance standards. Concluding, Stephen Keates, joint MD at ADS, said: “Holding BS EN 1090 is a legal requirement for any structural steel products that we manufacture for our clients. However, our rigorous internal audits and continuous improvement initiatives ensure that we not only meet but exceed these standards with quality and reliability that our clients can trust.” n ADS Laser Cutting www.adslaser.co.uk
6 July 2024 Production Engineering Solutions pesmedia.com NEWS In my line of work as an electrical engineer and retrofitter on machine tools I have seen too many major machine shops still running machines with control systems that I cut my teeth on in the 80’s and 90’s. The main reason these dinosaurs are still running is that they are a major asset and the investment required to replace them with modern equivalents is quite considerable, so they are kept running, often with known major issues, on a wing and a prayer. It’s no secret that there is also a dearth of quality machine tool engineers, throughout Europe, as a result of the downturn in manufacturing and skills training since the 1990’s. So, the people with the experience and knowledge to maintain these older systems are coming up to retirement age, with few replacements. Also, a dwindling resource is the spare parts and skills to repair the old systems. I recently sent an HMI off an old milling machine to the OEM for repair, and was told ‘That’s the last one, we have no more parts for those’. OEMs are also refusing to support the old legacy systems, so it’s left to the aftermarket repairers, some good, some not so good, and often quoting turnaround times of 3-6 weeks. That’s a long time to have your machine offline. Another consideration is that the technology required to communicate with and diagnose problems on these systems is becoming scarce. I still have an old Laptop running Windows XP with all the required data ports that you don’t get on new PC’s, and software that won’t run on them either. But when it inevitably dies that’s the end of it. I’m sure there are ways around it but is it worth the hassle? Also, factor in system obsolescence and reliability. How often do I see signs on control panels reading ‘DO NOT SWITCH OFF’, because it’s a toss of a coin whether the system will start up again, or not? The point is that if you are running these old systems you need to act now and get a retrofit that will revitalize the asset. Retrofitting is a costeffective upgrade for medium and large machines bringing several additional benefits other than having a contemporary control system. l Improved safety. l Reliability and supportability. l Spares availability. l Connectivity. l Data security. l Program download and backup reliability. l CAD/CAM productivity integration. l Current applications and design tools such as: Digital Twin modelling, Collision avoidance, Live uptime utilisation monitoring, Power usage and condition monitoring, Power optimisation. l Automation integration and upgrades: Robot/ Cobot/Auto-loading systems, Auto Tool Changing, Tool storage optimisation and planning. Basically, a modern control system retrofit will bring about significant cost & time savings and increase productivity. Get the most out of your old machines, give them a new lease of life. You should also consider mechanical refurbishment work to get the best out of your machine. We can do a full machine assessment, report and quotation. www.effectivecncsolutions.co.uk [email protected] CRUNCH TIME! EffectiveCNC_PES_hlfA4.indd 1 17/06/2024 08:48 Subsea demand drives growth at Express Engineering Yamazaki Mazak has appointed James Fell as its new area sales manager for the South West of England. He will take over from Tim Ponter, who is retiring after more than 30 years’ service at Mazak and nearly 50 years in the manufacturing industry. Mr Fell brings with him a wealth of experience in the machine tool industry, having trained as a CNC programmer and technical sales engineer before moving into business development roles. In his new role, he will assume responsibility for Mazak’s broad range of customers throughout the South West of England, with a particular focus on the region’s burgeoning subcontract manufacturing scene. Jason Butler, sales director at Yamazaki Mazak UK & Ireland, said: “It has been a pleasure to work so closely with Tim over the years and it is hard to put into words what he has achieved during three decades of service here at Mazak. We wish him all the very best with his retirement, however in James, we have a very capable sales professional who knows both the industry and the South West region exceptionally well.” Mr Fell added: “Early on in my career, I was fortunate enough to attend a programming course at Mazak and hoped to one day work for the company. The manufacturing community in the South West is thriving and given the breadth of Mazak’s portfolio, with a machine tool for every application and every price point, it’s a very exciting time to join the company. “I would like to thank Tim for the valuable insights he has shared in our short time working together before his retirement and wish him all the best for the future.” n Yamazaki Mazak www.mazakeu.co.uk/ James Fell (left) will be taking over from Tim Ponter as areas sales manager for the South West Mazak appoints new area sales manager for the South West Global demand in subsea markets for oil and gas continues to help drive growth at manufacturing, assembly and testing specialist Express Engineering, which is investing in capital equipment and its workforce. The international business, based in Gateshead in the North of England, has been enjoying buoyant growth during the last 12-18 months – growing its workforce while building a record pipeline of new work. Chris Thompson, chair of Express Engineering Group said: “The subsea sector is in a strong position for the next five years. I am delighted to say our order book has reached record levels, the highest in our 50-year history, and it’s only expected to increase further across the remainder of 2024. “With demand for product high, we hope to invest further in our capability this year, which will include a new CMM and horizontal borer to be situated in our Gateshead factories.” The current order book stands at around £70m for the next 12-18 months – with the group receiving an intake of £10m in new orders in the last month alone. Express Engineering has seen sales in the oil and gas sector grow significantly in recent years resulting in a jump in revenues from £20m in 2019 to more than £60m in 2024/25. Mr Thompson added that the acquisition of Middlesboroughbased QA Weld Tech in 2023 had made a positive contribution to the overall group. QA Weld Tech is a leading provider of integrated welding and engineering services. Building and strengthening the workforce and skill levels has been a major priority during the last year or more. Around 260 people work across multiple Team Valley sites for Express Engineering, while the headcount at QA Weld Tech has risen to 46. Managing director Gary Thirlwell added: “Our overall order book is so strong that we expect to increase our shift patterns and grow our headcount even further during 2024, both in Gateshead and Middlesbrough. We are looking to take on a lot more apprentices.” The group is looking to recruit fitters, assembly and test operators and CNC machinists at Express Engineering. Welders, platers and technical support staff are required at QA Weld Tech. Internationally, Express Engineering has become a renowned global supply specialist for actuator assemblies, connection systems and tooling for wellheads, drilling and subsea tree structures. The company is also getting involved in subsea carbon capture projects. n Express Engineering https://express-engineering.co.uk Sponsored content
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8 July 2024 Production Engineering Solutions pesmedia.com NEWS With the relentless rate of growth at Open Mind Technologies UK, the Bicester-based CAD/CAM developer has expanded its service team with the appointment of three new applications engineers – Gareth Clarke, Matthew Brill and Victor Fapohunda – to bolster its pre-and post-sales departments. Matthew Brill has accelerated his career progression since leaving school more than 10 years ago. He has completed a foundation degree in motorsport technology and from university, he worked as a mechanic for an international motor racing team before moving into manufacturing where he spent several years working for a high-end subcontract manufacturer in the motorsport industry. Joining the team alongside Mr Brill is Gareth Clarke, an engineer who started his engineering career more than 10 years ago. Working for a number of subcontract manufacturers, he has evolved from CNC machining and programming to becoming a team leader and subsequently head of programming in his final role before joining Open Mind. Completing the trio of new arrivals is Victor Fapohunda, an engineer who started his career pathway as an apprentice machinist almost a decade ago. He has since progressed as a machinist and more recently held down posts as a production lead with extensive programming experience with hyperMILL. Commenting upon the new additions and the strengthening of the team, Open Mind UK managing director Adrian Smith said: “Our business is continually growing in the UK and has outgrown our internal business model. “To further enhance our level of service and customer support we needed to restructure our application team and part of this has been to divide the team into pre- and post-sales engineers, giving them greater autonomy with customers and allowing dedicated experts to maximise their skillset to the advantage of the end user. “To implement this strategy, we needed to grow the applications team,” he added. “The appointment of Gareth, Matthew and Victor will certainly build upon our robust new structure and help us to deliver a foundation for future growth. “We are delighted with the new additions. To support their endeavours, we have added more internal resources such as dedicated hotlines, a new training room and ongoing enhancements to hyperMILL such as availability from the cloud. We are in an exciting transformational period and it is invigorating to have such a dynamic and enthusiastic team driving our brand.” n Open Mind Technologies www.openmind-tech.com New applications engineers at Open Mind: (L-R) Matthew Brill, Victor Fapohunda and Gareth Clarke Open Mind expands service team Call: 0800 043 1800 email: [email protected] www.cncrepair.co.uk ISO 9001 & ISO 45001 Accredited Super Precision Balancing To BS5265/ISO1940 Expert Technicians: Our technicians are highly skilled and experienced in diagnosing and repairing CNC spindles of all makes and models. Quick Turnaround: We understand the importance of minimising downtime. Our fast expedited turnaround time will get your spindle up and running in no time. Quality Guarantee: We use only the highest quality components in our repairs, ensuring optimal performance and longevity of your spindle unit. We stand behind our work with a 1 year guarantee, our rigorous testing protocols ensure that your spindle operates at peak efficiency before it leaves our facility. State-of-the-Art Facility: Equipped with cutting-edge technology and tools to ensure a back to original specification repair service. Whether your spindle develops a bearing failure, requires taper grinding / new drive dogs, a built-in motor rewind, drawbar retention issues or your spindle just requires balancing, we are here to get you back up and running. Competitive Pricing: Our services are affordable without compromising on quality, making us the go-to choice for all your spindle repair needs. Don’t let spindle issues slow down your operations. Trust our reliable team to restore your CNC spindle to peak performance levels! IS YOUR MACHINE TOOL LOSING ITS EDGE? Our expert manufacturer independent team specialises in CNC spindle repair with precision and excellence.
pesmedia.com Production Engineering Solutions July 2024 9 NEWS MADE IN USA Haas Automation | 01603 760539 | [email protected] The world’s best selling VMC for a reason. Auto Parts Loaders | Plug & Play Robots | Integrated Pallet Pools NEW www.haas.co.uk NEWS Bowers Group has announced the release of the Trimos V1 and V1+ height gauges. Designed for consistency and accuracy, the V1 offers user-friendly features for immediate application, guaranteeing reliable and precise measurements. “We are excited to introduce the Trimos V1 and V1+ height gauges to the UK market,” said Ryan Kingswell, UK sales manager at Bowers Group. “These instruments demonstrate our dedication to providing innovative solutions that meet the evolving needs of our customers. “With their user-friendly design and impressive precision, this range of height gauges offer an ideal solution for those new to precision measurement or looking to make the transfer from more traditional tools.” Set to replace the current mini vertical height gauge, the Trimos V1 is designed to be the ideal entrylevel instrument. Its intuitive design simplifies unidirectional measurements and tracing, providing users a simple transition from manual scribers to advanced height gauges. Building on the foundations of the V1, the V1+ offers enhanced capabilities for users looking for more advanced measurement options. With bidirectional measurement functionality, fine adjustment, and constant measuring force, the V1+ delivers versatility without the need for extra accessories. n Bowers Group www.bowersgroup.co.uk Bowers unveils new height gauges MRPeasy, a leading cloud-based manufacturing software provider for small businesses has announced reaching a significant milestone of maintaining 400 active clients in the UK. This achievement underscores the growing trust and reliance of UK-based small manufacturers on MRPeasy’s comprehensive software solution. “Reaching 400 active clients in the UK is not just a number for us; it represents the strong partnerships we have formed with UK manufacturers and our commitment to supporting the industry’s evolving needs,” said Sara Duff, UK business development manager at MRPeasy. In the past year alone, the company has made strides to further improve its platform, introducing the Master Production Schedule (MPS) and a B2B customer portal, alongside an innovative AI Chatbot designed to assist with software implementation and usage queries. These advancements, along with a plethora of more minor updates and added reporting capabilities, are part of MRPeasy’s ongoing efforts to tailor its offerings to the challenges faced by the small manufacturing sector. The celebration of 400 active clients comes just one year after MRPeasy marked the 300-client milestone in the UK, demonstrating rapid growth and the increasing adoption of MRP solutions. Globally, MRPeasy services 1,700 clients across 60 countries, with a strong presence in the UK, USA, Canada, and Australia. Recent surveys among MRPeasy users highlight significant efficiency and delivery accuracy improvements, with companies reporting an average 54% increase in operational efficiency and a 39% rise in the rate of on-time deliveries after implementing the software. n MRPeasy www.mrpeasy.com MRPeasy celebrates 400 manufacturing clients in the UK
10 July 2024 Production Engineering Solutions pesmedia.com NEWS As a leading provider of high-quality cutting tools and solutions, Waverley Cutting Tools has announced that it has entered a strategic partnership with Tooling Intelligence. The collaboration between the two leading companies designates Tooling Intelligence as the preferred inventory management supplier for Waverley Cutting Tools across Scotland. Located south of Aberdeen in Portlethen, Waverley Cutting Tools supplies Scottish manufacturers with a diverse portfolio of engineering products that range from cutting tools, measuring equipment, abrasives, oils and coolants, PPE, hand tools, welding equipment, consumables and more. Tooling Intelligence offers SupplyPro inventory management solutions and has remained exclusive to the brand since 2007. For manufacturers in Scotland, this partnership will benefit customers with streamlined inventory management through robust and scalable solutions allowing real-time tracking of tools, automated reordering of depleted stock and integration with existing ERP systems. Roger Kelman, director at Waverley Cutting Tools, expressed his enthusiasm for the partnership: “Tooling Intelligence offer a truly independent solution that allows us to utilise SupplyPro systems to their full potential with our customers.” Richard Swaffield, managing director at Tooling Intelligence concurred: “It’s been fantastic working in partnership with Waverley Cutting Tools. Roger and his team have a broad range of customers with a diverse set of requirements. It’s been a pleasure to ensure that our solution has been set up and integrated successfully to meet each customer’s requirements and exceed their expectations.” n Tooling Intelligence www.toolingintelligence.co.uk Over £200,000 of new equipment has been installed at Alloy Wire International (AWI) and is set to deliver more than £2m of additional capacity. The manufacturer of round, flat and profile wire has its two single hole blocks, three-hole dry drawing machine and four-spindle spooler now fully operational at its factory in the West Midlands. This will give the business the ability to reduce lead-times even further, while also allowing it to offer clients in the automotive, aerospace, defence, oil and gas and medical sectors with access to larger volume quantities. Bosses have also pressed the button on upgrading its tensile testing machinery, which will help it speed up the pre-job trial process and broaden the range of support offered to customers throughout the full duration of projects. “We had our best April on record for outgoing orders and the pipeline of activity shows no sign of things slowing down,” commented Andrew Du Plessis, technical director at AWI. “The decision was made last year to embark on a £500,000 investment drive and these latest installations are an important part of this strategy. Each one has been tailored to suit our specific production requirements and to have them operating on the shopfloor is great to see.” He continued: “Our success is all about making sure we are ahead of the competition when it comes to manufacturing agility, quality and delivery performance. The latter already sees us produce wire in three weeks – nobody else can do that. This investment reinforces this capability, as well as giving us nearly £2m of additional capacity to work with.” Alloy Wire International exports its range of 60 exotic alloys to 65 countries. This means material made and tested in its factories in Brierley Hill and Yorkshire is used as far away as Azerbaijan, Australia, Kuwait, Kazakhstan and India. The company has been trading internationally for 77 years, building a strong sales agent network with representatives on the ground in its core European, Chinese, Australian and US markets. This has really paid off in the US, delivering its largest ever export order (worth $400,000) to supply a high strength nickel cobalt alloy to a US spring maker. n Alloy Wire www.alloywire.com £200,000 machinery boost goes live at Alloy Wire Turning centre specialist CMZ has formalised the purchase of a 22,000m² plot in the Aboro district (Berriz-Vizcaya) in Northern Spain to build a new assembly plant. The area will be the setting for the manufacture of a new lathe model the company plans to bring to the market. Design work on the new machine is well underway. This builds on the investment made by the company in recent years with the intention of increasing capacity to 1,000 machines a year. The medium-term objective is to consolidate production of 800 lathes a year. This latest development will mean CMZ has eight plants for lathe production. The process has been designed so that over 80% of the components used in its machines are made via its own manufacturing ecosystem. This provides ultimate in-house control, eliminates import and export costs and enables the use of high-quality components without impacting on the final cost of the machine. As CMZ confirmed at the end of its last financial year, 2024 will see the company focusing its efforts on international expansion, initially through consolidation of its presence in Turkey and the United States with the support of its commercial network. The Group’s oldest subsidiary, CMZ France, which is about to celebrate its 20th anniversary, will also see a focus on increasing production. n CMZ www.cmz.com CMZ acquires 22,000m² plot in Spain for production ramp up Waverley sales director Roger Kelman (left) with Richard Swaffield, managing director at Tooling Intelligence Waverley chooses Tooling Intelligence as inventory partner
12 July 2024 Production Engineering Solutions pesmedia.com NEWS NEWS Group Rhodes, a Wakefield-based OEM active in the metalforming, composite forming and heavy ceramic sectors, has significantly expanded its workforce over the last six months to meet the needs of its ever-growing customer base across its four divisions. This includes six new staff for Group Rhodes, four for its Rhodes Interform division, four for the group’s latest addition, BJD Crushers and two for its Craven Fawcett business. Most of these new appointments are within the company’s manufacturing and machining operations. Mark Ridgway, OBE DL, chief executive of Group Rhodes, explained: “We are excited to have appointed these new staff members to meet the needs of our expanding order book. The acquisition of BJD Crushers at the end of 2023 has had a positive impact on our Craven Fawcett and Hallamshire Engineering Services businesses and has significantly strengthened our materials handling and heavy ceramic operations. We have also secured major contract wins in the composite and metal forming sectors.” He added: “It is hugely satisfying to report that our business continues to evolve and adapt to new market conditions in its 200th anniversary year. Relevance and product differentiation remain our key drivers in an increasingly segmented marketplace.” Group Rhodes has recently announced major new domestic contracts with companies such as Ibstock plc, Zentia and Cascade Manufacturing, and an additional 25% of the current order book rests with international sales. The company manufactures and markets its state-of-the-art machinery from its factory in West Yorkshire, which it sells to both the UK and global markets. The company has extensive capabilities including the design, development and manufacture of bespoke equipment and the provision of complete turnkey solutions. BJD Crushers, Craven Fawcett and Hallamshire Engineering Services manufacture machinery and spare parts for the aggregates, heavy clay and materials handling sectors, whereas Rhodes Interform focuses on the design and manufacture of machinery to serve the advanced metal and composite forming industries, with a particular focus on the aerospace sector. 2024 marks the company’s 200th anniversary year. From its early days in 1824 when Joseph Rhodes opened his first machine workshop in Wakefield, to Group Rhodes today supplying machinery equipment solutions to manufacturers throughout the world, the company has shown both resilience and adaptability. Its sovereign capability has been previously recognised by Queen’s Awards for Enterprise in both the Innovation and International Sales categories. n Group Rhodes www.grouprhodes.co.uk Group Rhodes’ chief executive Mark Ridgway Group Rhodes goes for growth in its 200th year The bridge type CNC CMM offers both high-performance and cost-effective measurements. Achieves high-speed measurement and high-accuracy of (1.2+3L /1000) μm. Suitable for measuring medium-sized workpieces accurately. Thermal compensation is equipped as standard Scan here to discover more about STRATO-Active or visit: www.mitutoyo.co.uk/strato-active
pesmedia.com Production Engineering Solutions July 2024 13 NEWS Want to win work in nuclear? The Nuclear AMRCʼs Fit For Nuclear programme has helped hundreds of UK manufacturers to assess and develop their capabilities for nuclear customers. So far, F4N-granted companies have reported that our support has helped them win more than £2.1 billion of new contracts. We have now enhanced and expanded the F4N programme, with new support to help manufacturers of all sizes to win work across the nuclear sector. namrc.co.uk/services/f4n Skills remain a key priority for manufacturers, with a recent report revealing that training budgets have not been hit by rising inflation. 86% of firms questioned in the annual In-Comm Training Barometer said that their spending intentions have remained unchanged, with more than three quarters investing in new technology to boost productivity – an 8% rise on last year’s findings. The survey, which features the views of 113 bosses, also reveals that 61% are planning to take on an apprentice over the next 12 months. Furthermore, the vast majority (72%) believe that there isn’t enough national government support for training, with 44% wanting better funding for apprenticeships and 39% to boost upskilling. “The last 12 months have been dominated by global pressures outside of industry’s control, with a cocktail of difficulties ranging from supply chain disruption and conflicts in Europe to far reaching political uncertainty and high inflation,” explained Gareth Jones, managing director of In-Comm Training. “With all these pressures, we are pleasantly surprised that so many businesses have prioritised meeting their skills gaps over cutting budgets in the face of soaring prices. This shows an overwhelming desire by our sector to support the development of apprentices and to address the burning issue of skills, making sure that a lack of talent – both now and in the future – is not a barrier to UK manufacturing making the most out of its recent resurgence. “The stat around government support highlights a disparity with the local picture, which is a lot more optimistic and responsive to employer needs,” he added. “A prime example is a funding boost we received from the West Midlands Combined Authority (WMCA) to support the introduction of more modularised training, helping management teams overcome the issue of releasing staff from core operations. “Local Skills Improvement Plans, supposedly set-up to drive industryled investment on a national basis, have so far failed to support the direct funding of modular programmes. And this despite 83% of bosses saying they would take up the opportunity of modularised training if funding was in place. “Another area of concern is the vast amount of youth unemployment among NEETS (not in employment, education or training). Having access to funded training programmes, tailored to specific engineering needs, could really help get people into the hundreds of jobs available in industry.” To download the full report visit the In-Comm website. n In-Comm Training www.in-comm.co.uk Localised skills funding has made innovative employment training programmes with Collins Aerospace possible Skills and training still a priority for manufacturers
14 July 2024 Production Engineering Solutions pesmedia.com NEWS Contact us now to discuss your needs: +44 (0) 1723 582 868 I [email protected] unisonltd.com • 50 mm or 80 mm CNC tube bending machines • Exceptional power and robust mechanical design • Dual-stack bending – for reduced tool changes • Designed for repetitive tube bending tasks • Choice of industry-leading motors and drives • User-friendly Unison touchscreen control Unison quality – at a highly accessible price! Unison Synergy Hybrid, dual-stack tube bending machines Citizen Machinery UK’s stand at MACH was busy over the five days, with 538 manufacturing companies making enquiries that required further action. The level of visitor interest was especially high as Citizen had decided to defer a 5% price increase on its Cincom slidinghead and Miyano fixed-head lathes until after the show. A total of 29 orders valued at very close to £5,000,000 were placed either during the event, or afterwards as a direct result of it. All nine machines exhibited, spanning the bar capacity range 12mm to 80mm, were under power and five of them made separate parts that were assembled by visitors into a giveaway component. Star of the show was the Miyano BNE-65MYY, which employed the versatility of Citizen’s superimposed machining to produce an impressively complex part in about 2.5 minutes. Robotic automation on a Miyano BNA-42SY5 was another highlight, while the Cincom L32-XLFV utilising the company’s LFV chip breaking technology to cut plastic also created a lot of interest. Richhill-based subcontractor Rosco Engineering in Co Armagh placed an order at MACH for a Cincom L20XIIB5LFV sliding-head lathe. Production of hydraulic parts, which accounts for 15% of the company’s turnover, is a pricesensitive undertaking. In 2006, the company purchased its first Citizen lathe, a larger capacity L32, reduced a three-operation process taking seven minutes to a single, four-minute cycle. The time to produce this 303 stainless steel part should be reduced by a further 50% by the smaller, more agile L20, doubling productivity. General manager, James Scott commented: “Not only will the new slider be more productive, but it will also save an extra shift adding to the financial benefit. We machine a lot of stainless steel and plastic in addition to mild steel, so Citizen’s low frequency vibration (LFV) function will help with chip breaking, while high pressure coolant will ensure uninterrupted production of parts requiring deep hole drilling. Both swarf management techniques should significantly extend tool life.” The highly specified lathe also has extra toolholders and a swivelling B-axis tool carrier that extends the machine’s versatility when executing angled cross-working or end facing operations. Now that MACH is over, thoughts have already turned to the annual Citizen open house at its Brierley Hill facility in October, where the company will continue to celebrate its 50th anniversary. Citizen Machinery UK www.citizenmachinery.co.uk Citizen reports best ever MACH Xtreme Motorsports, which manufactures high-quality performance car upgrades for motorsport racing, has overhauled its production thanks to an implementation of Fortee, Forterro’s entry-level cloud-based ERP solution, helping it to remain competitive and improving profitability. The company, which specialises in Nissan GTR-R35 clutch upgrades, had previously relied on traditional tools such as spreadsheets and extensive paperwork to manage the different stages of production. The implementation of Fortee marked a huge shift for Xtreme Motorsports. Fortee’s ability to handle optimum batch sizes and streamline complex manufacturing stages, such as in CNC machining, drastically reduced the business’ time and resource wastage. This shift from smaller, inefficient batches to larger and more cost-effective quantities has been transformative for staying competitive. “It is so satisfying to be in control of everything – overseeing costings, routings, the bill of materials and the structures,” said Antony Allsop, business development manager at Xtreme Motorsports. “It gives a sense of being on top of everything and knowing exactly where we are headed. The business is now positioned for significant expansion and diversification over the next few years.” Stock management and planning were major pain points for Xtreme Motorsports and meant a reactive and disorganised approach. The implementation of Fortee introduced a much more proactive strategy, enhancing control over inventory and stock levels. This new system reduced the instances of running out of key items, which had previously led to lost orders and customer retention issues. “Because of Fortee, there’s been less panic and knee-jerk reactions across the business,” continued Mr Allsop. “We have a number of new and ambitious projects in the pipeline and the Fortee cloud ERP has been a central component in ensuring we are ready for those projects and for accelerating our digital transformation.” Launched in the UK in May 2024, Fortee is an out-ofthe-box SaaS ERP solution designed for the specific requirements of SME discrete manufacturers and industrial startups. It is based on Forterro’s successful cloud ERP solution Sylob and is the result of 15 years of cloud-ERP learning and development. “Using spreadsheets and paper-based processes is still common among many smaller manufacturers,” commented Benoît Wambergue, VP of product management for Forterro. “It really doesn’t need to be though. A cloud-based ERP such as Fortee is incredibly easy to get started with, and Xtreme Motorsports was up and running and seeing ROI in a matter of weeks.” n Forterro www.forterro.com/en Xtreme Motorsports manufactures Nissan GTR-R35 clutch upgrades Fortee ERP helps Xtreme Motorsports accelerate digital transformation
The dynamic, accurate and powerful multi-axis Zayer ZERO. Just one model from Zayer’s impressive range of large-capacity multi-tasking CNC horizontal bed mills available from Mills CNC. The ZERO is a real hero in the machine shop and is equipped with a large worktable (up to 4,000mm x 1,000mm), a 40-tool magazine, a powerful 30kW/6,000rpm (up to 8,000rpm) spindle, and up to 4,000mm x 1,200mm x 1,600mm X/Y/Z travels. The machine can handle a range of large applications, including big mould tools, and is used extensively, throughout the world, machining precision components used in the aerospace, oil and gas, renewables, automotive and rail sectors. Where high part accuracies and short lead times are the order of the day, you can rely on the ZERO to deliver. To find out more about the ZERO, and other CNC horizontal bed mills from Zayer, call Mills CNC on 01926 736736 or visit www.millscnc.co.uk Mills CNC: Like No-one Else! The proven and reliable Zayer ZERO CNC horizontal bed mill from Mills CNC. There’s Zero chance of it ever letting you down.
16 July 2024 Production Engineering Solutions pesmedia.com MACHINING New machine tool company hits the ground running As far as machine tool manufacturers go, Syil may not be a brand name that immediately rolls off the tongue, but the company has actually had a UK presence – albeit somewhat restrained – since 2011. Now, coinciding with Titans of CNC selling the brand in the US, Syil CNC UK officially launched in May this year. In this Q&A, Dave Tudor caught up with technical director Lee Wilkinson to learn about the new company’s goals and aspirations. Q Before we get onto the new UK operation, tell me a bit about Syil from a wider perspective? A. Syil is a global CNC machine tool brand, headquartered in China whose roots stem back to 2001. Today, the company boasts 17 global dealers and 12,000 machines sold globally. With a solid emphasis on using bestin-class components available from such esteemed brands like Schneeberger Switzerland, THK Japan, Siemens, FANUC and Heidenhain, we enhance this by delivering a second-to-none personalised service sold by engineers for engineers – all at an unrivalled price point. In the US, this is the first brand of CNC machine tool officially sold by the engineering behemoth Titans of CNC who have a fantastic reputation globally with over 400 million views on their YouTube channel. We are proud to say we are officially working with the team over in the USA as we are both official Syil partners. We have some really exciting developments coming our way, in particular with how we support education in the UK. Q. Where does the actual machine manufacturing take place? Is it purely in China or are there manufacturing facilities elsewhere? A. To give Syil such a competitive price point while using many ‘gold standard’ components, machine assembly takes place at the main site in China. The machines are a combined global effort, with epoxy granite castings from Schneeberger Switzerland, ballscrews and linear motion guides from THK Japan and sheetmetal parts supplied directly from Germany. We offer a choice of control systems such as Siemens, FANUC and Heidenhain as well as CAMbased controls like Syntec and LNC. We also provide single phase options. Make no mistake on quality. Our main factory has over 100 highly trained staff with each and every machine undergoing a strict geometric PDI using Renishaw interferometer lasers and ballbar kits as standard. With two-year warranties as standard, extendable up to five years, we have our customers covered. Q. Let’s get on to the UK operation. How long have Syil had a presence in the UK? I must admit it’s not a brand I’ve heard of. A. Syil has had a minimal UK presence since 2011 but were never well-known. Fast forward to 2024, with Titans of CNC now personally choosing to sell Syil machines in the USA along with a major shakeup using only the highest quality parts during manufacture, growth plans have accelerated rapidly. The new UK team – comprising Patrick O’Connor, Tom Marshallsay and myself as technical directors – was formed to drive business and promote the brand here in the UK. We began trading as Syil CNC UK Ltd in May 2024. The initial interest in the brand has been fantastic. We’re a company that aims to provide a personal one-to-one service delivered by knowledgeable and experienced people who have lived and breathed the industry for many years. Between the three of us, we’ve amassed a combined 40 years’ experience across all aspects of high-level machining ranging from 3- to 5-axis simultaneous milling through to complex live axis turning and microSwiss machining as well as developing cutting strategies, CAM programming and the development and research of tooling. Over the years, we’ve all enjoyed working across multiple sub-sectors such as F1, automotive, medical device manufacture, aerospace and defence, and oil & gas. In terms of premises, currently we have an office in Sheffield with a showroom opening in August close to the Advanced Manufacturing Park. In addition to the three directors, we also have a contracted service partner working with us to enable more capacity. We can offer a full turnkey service that encompasses not only the machine but the whole package – from the engineering drawing to a fully optimised production process and everything in between. Q. Tell me about your product range for the UK market? Will you stock machines here? Will these be ‘standard’ off the Syil CNC UK directors (L-R) Tom Marshallsay, Lee Wilkinson and Patrick O’Connor Syil CNC UK directors and global Syil partners with the Titans of CNC team
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