PES Media Production Engineering Solutions June 2024 pesmedia.com On a mission ukmfgnews Sustainable and responsible manufacturing from Ceratizit Pages 20-22 Preview pages 37-39
SINCE 1984 XYZ Showrooms | Livingston| Huddersfield | Sheffield | Nuneaton| Devon| Zabrze 01823 674200 | [email protected] | www.xyzmachinetools.com XYZ MACHINE TOOLS, WOODLANDS BUSINESS PARK, BURLESCOMBE, TIVERTON, DEVON. EX16 7LL EXHIBITORS INCLUDE 40TH ANNIVERSARY TECHNOLOGY EXHIBITION Visit the website for more details and to pre-register TUESDAY 9th & WEDNESDAY 10th JULY 2024 9:00am – 3:00pm MACHINE TOOLS WOODLANDS BUSINESS
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www.pesmedia.com Production Engineering Solutions June 2024 3 It’s been five years since I last visited Ceratizit’s sites in Germany and Austria so a press event planned for April this year would be a good barometer of the company’s progress and development. And there certainly was plenty to see – evidenced by my cover story on pages 20-22. In fact, the tooling giant has invested literally hundreds of millions of Euros in new facilities in Reutte, Austria, and Kempten in Germany. With the former, there’s a brand-new production factory in Kreckelmoos (located in the Tyrol region of Austria), and in Germany there’s a new Logistics Centre AND a new sales headquarters and Technical Centre. It’s generally accepted that if you don’t invest in your business, you effectively stand still at best, or fall behind the competition at worst. Ceratizit certainly can’t be accused of that! There’s lots of good stuff going on, but the company’s commitment to sustainability and the environment is a thread that touches everything it does. Not surprisingly the subject underpinned proceedings at the press event: Ceratizit has adopted an ‘umbrella’ term to describe its environmental endeavours: ‘connACT – Together for Sustainability’. The tooling manufacturer is taking its responsibilities very seriously indeed. At the press conference, board member Melissa Albeck declared the company’s vision to become “the leading company for sustainability across the entire carbide industry,” describing it a mission rather than a goal. As carbide is such a valuable resource, reclaiming it from scrap, both internally and from customers is a priority for Ceratizit. R&D director Dr Uwe Schleinkofer went so far as to describe scrap carbide as “the new gold in our business.” And this isn’t simply paying lip service to its environmental responsibilities or falling foul of unscrupulous greenwashing practices. Drilling down (no pun intended) into its tooling ranges, the company has introduced a Product Carbon Footprint (PCF) rating on all its products. In basic terminology, a carbon footprint is used to calculate how much greenhouse gases are emitted by a person, company, or country – and CO2e is a metric used to standardise the climate impact of different greenhouse gases. With its PCF ratings, Ceratizit effectively calculates how much CO2e is emitted during the production process across its product range meaning it can determine the specific carbon footprint in kg CO2e per kg product. The calculation is made by taking all upstream direct and indirect emissions into account. Indirect emissions are all released gases along the upstream supply chain, as well as energy suppliers. Direct emissions are the release of climate damaging gases within the production process. Importantly, the calculation (and subsequent A to F rating) encompasses every step in the production cycle, from raw material extraction to the final steps in the production process. So when a customer buys a tool from Ceratizit, the buyer knows its carbon footprint – the PCF rating has been integrated into the company’s billing system and can be found on every invoice. Why is this important? Well as businesses around the world evaluate their own respective carbon footprints, it’s all about transparency up and down the supply chain. I think this is a really positive initiative from Ceratizit and it’s one that all manufacturing companies need to adopt. Dave Tudor Editorial Director A common thread that drives all successful companies is an unrelenting desire to evolve, adapt to ever-changing market conditions and consistently invest in people and technology. For some businesses however, like the Ceratizit Group, it’s much more than evolution – it’s a passion, as Dave Tudor discovered during a recent international press event held at its sites in Austria and Germany. See pages 20-22 Cover story COMMENT/CONTENTS 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. No part of this publication may be reproduced or transmitted without the consent of the publisher. © MIT Publishing Limited 2024 You can now view your copy of Production Engineering Solutions online. To register, please go to www.pesmedia.com Contents PES has strict circulation terms of control. These are independently verified and audited by the ‘Audit Bureau of Circulations’. Circulation Statement Published by: MIT Publishing Limited, Featherstone House, 375 High Street, Rochester, Kent ME1 1DA Tel: 01634 830566 Volume 28 Issue 338 ISSN 1460-3926 EVENTS September 2024 UK Metals Expo NEC, Birmingham, UK 11-12 September 2024 July 2024 Farnborough International Airshow Farnborough, UK 22-26 July 2024 5 Electricity connection agreed for Port Talbot’s greener arc furnaces King’s Award for exports goes to Cambridge Precision NEWS TOOLING & WORKHOLDING 19 Next generation of Makro Grip vices from Lang On a mission MACHINING 16 Bumotec solves medical production puzzle Hercules: engineering across continents TURNING 24 Swift set-ups settle slider purchase HONING & DEEP HOLE DRILLING 26 Working in tandem with new aligned tools Adding automated loading for deep hole drilling QUALITY & INSPECTION 29 Bowers boosts efficiency at Alrose Products Eumetron GmbH: a point of reference 34 AI advances for CAM programming Taking up templates to increase productivity FARNBOROUGH INTERNATIONAL AIRSHOW 2024 37 Farnborough on track for thriving aviation business FANUC focuses on next generation aerospace automation AEROSPACE & DEFENCE 40 WFL machines manufacture key components for aerospace Bright Engineering develops long-term growth opportunities in aerospace and defence Circulation Perception SAS Phone: 01825 701520 [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 CAD/CAM
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pesmedia.com Production Engineering Solutions June 2024 5 NEWS COMPANY FINDER 1st Machine Tool Accessories 27 Accretech SBS UK 29 Airframe Designs 42 Alrose Products 29 ANCA 14 ANT Industries 10 ASG Arrowsmith 13 Boeing 14 Bowers Group 6, 29 Brandauer 14 Bright Engineering 41 Cambridge Precision 5 Ceratizit UK & Ireland 20 Citizen Machinery UK 24 CloudNC 34 Dawnlough Precision 16 delapena 26 FANUC UK 38 Farnborough International Airshow 37 h2m Engineering 24 Haas 17 Heller 38 Hercules 17 Horizons 10 Hurco 9 Lang Technik 19 Manchester Metrology 33 MSC 9 NCMT 6 Renishaw 30 Starrag 16 Status Metrology Solutions 30 Tata Steel 5 Tebis 36 Tooling Intelligence 12 Unison 8 WFL Millturn Technologies UK 40 XYZ Machine Tools 8, 18 1st Machine Tool Accessories 15 Akyapak 9 Allied Machine & Engineering 19 Bowers Group 32 Ceratizit UK & Ireland 44 CloudNC 36 delapena 28 Electro-Wind 10 Fladder 37 Haas 13 Horn Cutting Tools 23 Iscar 4 Lang Technik 5 Lantek 35 Manchester Metrology 31 MecWash 41 Mills CNC 7, 11 Muffet Engineering Solutions 42 NCMT 17 NJ Metrology 29 Nuclear AMRC 12 Star GB 25 Status Metrology Solutions 30 Subcon Drilling 27 Swissmatic 40 Sykes Machines 8 TBT 26 Tebis 34 Tooling Intelligence 6 Vision Engineering 33 Ward Hi-Tech 39 XYZ Machine Tools 2 EDITORIAL ADVERTISING NEWS âââĜ®yµljÒ µ¡¬ĜºĜÖ¬ʼnʼn Electricity connection agreed for Port Talbot’s greener arc furnaces Tata Steel has achieved a major milestone in its transformation of the Port Talbot steelworks after signing a connection offer with the Electricity System Operator (ESO). The agreement involves National Grid building new electrical infrastructure capable of powering the 3.2 million tonne electric arc furnace by the end of 2027. Tata Steel UK’s CEO, Rajesh Nair, said: “I’m delighted we’ve signed this connection agreement with the ESO. This is a critical milestone in transforming our steelmaking operations in Port Talbot and will help us replace our ageing and carbon intensive blast furnaces with a state-of-theart electric arc furnace capable of producing our customers’ most demanding steel products.” Industry Minister Alan Mak said: “This is another positive step towards securing the future of steelmaking in South Wales and the UK, and I’m pleased to see Tata Steel reach this milestone. “Our support for the steel industry is unwavering, and our historic investment alongside our grid capabilities means we can look ahead to cleaner, greener steel production in years to come. Accelerating grid connection timescales is a top priority for government and we are working closely with Ofgem and the network companies to transform the electricity network at a scale and pace not seen for decades.” Mr Nair added: “Having access to higher power electricity is a foundation stone for greener steelmaking, regardless of the technology choice. That’s why we’ve been working closely with the ESO and National Grid for a number of years on how to strengthen our power infrastructure. “This agreement means we will have sufficient power for our new electric arc furnace and the capability in the longer-term to further strengthen our business.” Q Tata Steel www.tatasteeleurope.com Cambridge Precision has been announced as a recipient of the King’s Award for Enterprise for International Trade. The King’s Awards for Enterprise are the most prestigious awards for UK businesses, recognising and celebrating business excellence across the UK. Cambridge Precision Ltd (CPL) is one of only 252 organisations nationally to be honoured this year with a King’s Award. Tony Murray, commercial director said: “What an achievement. For all our team who have, time and time again, gone the extra mile and found a different way, this award is rightly yours.” The long-established Queen’s awards programme was renamed last year to reflect His Majesty the King’s commitment to continuing the legacy of HM Queen Elizabeth II, who initiated the scrutinising awards programme. Now in its 58th year, this is the most respected business award in the country. Employing 83 people, CPL was founded in 1991 and today is widely acknowledged in tech innovation and bio-med technology sectors as a production partner of choice for consequential precision engineered components and subassemblies. For CPL, establishing a dedicated production unit for export and working collaboratively with clients (based overseas or requiring alliance with international suppliers and distributors) has been a key focus over the last five years. Acting in partnership with customers to overcome trade barriers and implement sustainable global supply chains has helped the business to develop greater agility and develop as an organisation within the global market. Richard Hefford Hobbs, chairman added: “Our clients come to us for our expertise in manufacturing complex components, critical to the performance of their product. They stay with us and develop long-term partnerships because of our continuous commitment to helping their business succeed. “Developing our international trade over the last five years was a deliberate objective – which proved challenging, thanks to the pandemic, material shortages and evolving trade agreements – however the relationships we have built are stronger and more aligned than we could ever have imagined. It’s been a tough but a beneficial journey. Being recognised by a King’s Award is something we value immeasurably.” Q Cambridge Precision https://cambridgeprecision.com/ King’s Award for exports goes to Cambridge Precision
6 June 2024 Production Engineering Solutions pesmedia.com NEWS Bowers Group has launched a summer promotion, offering an impressive 20% off its bestselling products. This limited-time-only promotion offers businesses a great opportunity to access high-quality gauging solutions at a discounted price. With a full range of sizes included, customers can find the right gauges for their needs. “We’re excited to kick off the summer season with this special promotion,” said Ryan Kingswell, UK sales manager at Bowers Group. “We’re committed to providing our customers with the best possible solutions to meet their measurement needs. This promotion allows us to offer our bestselling gauges at a significant discount, making precision measurement more accessible than ever before.” From the well-established XT3 bore gauges to the popular Universal Gauge set, selected promotional products include an array of measurement tools designed to enhance accuracy and efficiency across various industries. With Bowers Group’s reputation for quality and reliability, customers can trust that they are investing in products of the highest calibre. “Bowers’ gauging sets are essential tools for any quality conscious manufacturer,” Mr Kingswell added. “The XT3 is known for its advanced electronics, providing precise and repeatable measurements, making it ideal for various applications. In addition, the Universal Gauge is also highly versatile and can be used across a wide range of larger measurement tasks, ensuring reliability and accuracy.” To take advantage of the offer, visit the Bowers Group website or contact sales@bowersgroup. co.uk to learn more about the selected gauges included in the summer promotion. This is a limited time opportunity which expires on 31st July 2024. Q Bowers Group www.bowersgroup.co.uk Summer savings on deals from Bowers Group The increasing use of digitalisation in manufacturing environments is creating new opportunities for cybercrime, making it essential for companies to implement appropriate protective measures. For this reason, Okuma CNC machine tools are equipped with powerful security functions as standard. They ensure optimal cybersecurity and enable data recovery if necessary. In the UK, Okuma is represented by NCMT. Intelligent control systems contribute significantly to more efficient, accurate and resourcesaving production, making it easier even for inexperienced operators to perform complex machining operations. However, as machine tools become more connected, the threat of cyberattacks increases significantly, as does the number of companies affected. The risk goes far beyond production downtime and the associated financial loss. Cyberattacks can lead to the complete mechanical destruction of production technology. In the worst case, they can even endanger human lives. For this reason, Okuma has integrated robust security features into its intelligent, proprietary OSP-P500 CNC. The company has chosen a three-step solution. For comprehensive risk management and preventive protection, the features prevent manipulation attempts and detect anomalies and program manipulation at an early stage. Advanced user identification processes prevent unauthorised access to the control and machine interfaces, ensuring real-time protection. In addition, regular backups of the control software and data ensure reliable data backup and recovery. The whitelist feature completes the security solution where companies can determine which applications are allowed to run on the machine. In this way, Okuma meets individual production conditions as well as the highest security requirements, enabling stable, uninterrupted production at all times. Programs that are not on the list are prevented from running. This protects the machines from viruses or malware. Q NCMT www.ncmt.co.uk Smart machine control with integrated security solution Scan here for more Bowers Group articles Scan here for more NCMT articles
New DN Solutions’DVF 4000 simultaneous 5-axis machining centres. Admire. Aspire. Acquire. 3. The Commercial Angle: Easier to Acquire. • Low deposit* • 3 month payment holiday* • Attractive terms (favourable monthly repayments)* * (Subject to status) For those component manufacturers still ‘umming and ahhing’ about investing in a new 5-axis machining centre, we now believe we can put any concerns and anxieties you may have to bed. Once and for all. If you’ve not invested in a 5-axis machine before, or if you’re looking to increase your 5-axis machining capabilities further, our new DVF 4000 machines, from a technical, commercial and operational perspective, have all the angles covered. DVF 4000 5-axis machines: first choice if you’re new to the technology, and first choice if you’re not. To find out more about our new DVF 4000 machining centres call us on 01926 736736 or visit www.millscnc.co.uk Mills CNC: Like No-one Else! 1. The Technical Angle: Lots to Admire. • Compact machine • Direct-coupled, high-torque spindle (18.5kW/12,000rpm) •Thermal compensation • Fanuc iPlus control with advanced, easy-to-use iHMI 2. The Operational Angle: Be Inspired. • Fast part processing • Improved flexibility and process efficiencies • Immediate delivery
8 June 2024 Production Engineering Solutions pesmedia.com NEWS Unison has introduced a ‘refurbish and re-control’ service specifically for Addison tube bending machines. The service has been designed to provide owners of Addison tube benders with a cost-effective, quality assured means of upgrading their older machines with the latest operating technologies, for enhanced levels of control, productivity and performance. It involves the use of Unison’s latest servo-drive platform, new control and drive chassis plates, a replacement machine controller, an updated safety PLC, and a new Windows 11 PC running the latest version of Unison’s advanced Unibend CNC. All replacement parts are covered by a comprehensive warranty, and a full machine inspection and condition report is included. A detailed quotation is provided prior to work commencing and additional operations can be included if required. Back in autumn 2022, Unison recruited a number of former key employees from the recently defunct Preston-based Addison Forming Technologies Ltd (previously known as Addison McKee). “With new Unison technologies in the pipeline and exciting long-term strategic plans our aim at the time was to employ as many of the former Addison team members as we could justify, in order to keep their considerable skills in the UK,” commented Unison’s joint managing director, Alan Pickering. “It was a move that helped grow our consumable tooling offering in particular, as well as expand our reach both at home and overseas. “However, talking to users of Addison tube bending machines over the last 12 months led us to realise that a very real need also existed for a refurbish and re-control service tailored to Addison tube benders. With this in mind, we set about creating a refurbishment and re-control offer specifically for owners of Addison models.” Re-controlled Addison tube bending machines benefit from Unison’s proprietary Unibend CNC. This Windows-based system allows for ease of setup and network integration of various coordinate measuring machines, while existing tube bending templates can be easily modified to adapt to new part requirements. By using TeamViewer connectivity software in conjunction with its Unibend CNC, Unison can also remotely access both machine and data, to help resolve issues and assist with new application requirements – often eliminating the need for a site visit. Unison’s new refurbishment and re-control offering for Addison bending machines follows on from its recently launched consumable tooling service – the result of a £750,000 investment. Q Unison www.unisonltd.com www.sykesmachines.com WE RE-MANUFACTURE W.E SYKES GEAR MACHINES! Shinora SR2 CNC Rack Cutting Machine fully rebuilt for Sale Maximum Cutting Length 1500mm, Maximum Module 8 Suitable for Spur & Helical Racks ( 30 deg ) , Siemens 3 Axis CNC Control W.E SYKES GB LTD contact: ++ 44 (0) 7860 345 343 [email protected] Unison launches refurbish and re-control service for Addison tube bending machines Scan here for more Unison articles XYZ Machine Tools will celebrate 40 years of product and service excellence by staging a showcase technology exhibition at its 100,000ft² headquarters and manufacturing facility in Burlescombe, Devon. Taking place from 9-10 July 2024 (09:00 to 15:00), this technological and commercial show of strength will demonstrate why the company has become the UK’s largest supplier of CNC machine tools. “To celebrate 40 years of trading we’ll show our full product range, everything from manual machines, ProtoTRAK mills and ProtoTRAK lathes, through to a broad spread of other CNC machines that include 5-axis machining centres and sub-spindle lathes,” explained managing director Nigel Atherton, who founded XYZ Machine Tools in 1984. “Also present will be 17 invited partner companies offering complementary products and plementary products and services, making it a onestop-shop for anyone looking to invest in the future of their business.” Visitors to XYZ’s technology exhibition can expect a number of event highlights, including innovative machining demonstrations involving both ProtoTRAK and Siemens controlled machines. Among the models taking the spotlight will edge technology with the latest performance specifications, making it ideal for the highspeed, high-precision machining of complex components in a single set-up. To support these machine tools and help progressive manufacturers take their operations to the next level, leading solutions from invited exhibitors will focus on technology areas that include metrology, cutting tools, oil mist extraction, tool holding, work holding, CAD/CAM software, CNC systems, barfeeds, slidinghead lathes, lubricants, digital readouts, EDM machines and more. During the event, XYZ will also host two tours (AM and PM) of its state-of-the-art factory at Burlescombe, with more daily tours possible if demand is high. A hog roast lunch and a range of hot and cold beverages will be available throughout the day. All visitors will also receive a complimentary goodie bag. XYZ advises early registration by visiting the link below or scanning the QR code. XYZ Machine Tools www.xyzmachinetools.com/ event/40th-anniversary-technicalexhibition be the new XYZ 65 LTY-S. This advanced sub-spindle turning centre automates the complete machining of parts requiring both turned and milled features. Another model taking pride of place at the exhibition will be the XYZ UMC-5X simultaneous 5-axis machining centre with 15,000rpm spindle and 90rpm high-torque table. This machine combines cuttingXYZ celebrates milestone anniversary with technology exhibition TY-S The new XYZ 65 LT star will be among the s attractions
NEWS MSC Industrial Supply Co. UK (MSC) and Hurco Europe have signalled a closer commercial relationship by forming a strategic partnership. MSC’s Tech Centre now houses two of Hurco’s latest machines. The investment sees MSC install its first 5-axis machine tool – a Hurco VMX42SRTi table head configuration milling machine with a high-torque spindle capable of 12,000rpm, and a generous 1,067mm x 610mm x 610mm working envelope including a 600mm diameter C-axis rotary table, which can be used for secondary applications. The VMX42SRTi is joined by a Hurco TMX8MYSi slant bed lathe with sub-spindle, parts catcher, Renishaw tool setter and additional Y-axis capability for straight-wall or flat-bottom pocket milling and off-centre machining operations. The new machines join a host of advanced manufacturing technology already installed at the Tech Centre which also features a 165-inch display wall for live-streaming machining activity on the two new Hurco machines via a Rotoclear 4k camera system. MSC’s Tech Centre, located at its UK headquarters in Wednesbury, was launched in 2022. It provides a live-cutting facility where MSC engineers and customers can work together to optimise machining processes. The formalising of the partnership means MSC’s customers will experience the quality of the Hurco machines during tests and Tech Centre open days, while any of Hurco’s customers who can’t travel to its showroom in High Wycombe can arrange to come and see the two machine tools in action at MSC’s facility. Matt Garbett, Tech Centre manager at MSC said: “All of our engineers have now been fully trained on the Hurco machines and we’re all blown away by their technical features and build quality. Since their installation, the centre has been a hive of activity with our engineers delivering customer projects, cost savings and supplier tooling trials.” Gareth Evans, head of engineering at MSC added: “Our partnership with Hurco offers a huge opportunity for collaboration, which will benefit both MSC’s and Hurco’s customers alike.” Hurco Europe managing director David Waghorn enthused: “We really appreciate the fact that the people at MSC are so committed to learning and getting the best out of the Hurco machines. This new partnership will ensure that customers get the best possible service. Nothing can beat live cutting demonstrations from engineers with in-depth product knowledge. We look forward to working together with MSC in the future.” Q MSC www.mscdirect.co.uk www.mscdirect.co.uk/engineeringtechnology-centre Hurco partnership strengthens MSC’s engineering support Scan here for more MSC articles Scan here for more Hurco articles Q Hurco www.hurco.com/gb
10 June 2024 Production Engineering Solutions pesmedia.com NEWS ANT Industries, a precision engineering firm headquartered in Atherstone, Warwickshire, is celebrating a year of unprecedented success and growth, announcing orders in excess of £30 million won over the next three years. Specialising in the manufacturing of components for aerospace and gas turbine engines, the company has emerged as a leading centre of excellence in the industry. With a robust balance sheet in 2023, the business has continued to establish itself as a key player in the aerospace engineering sector. Bolstered by multi-million pound orders, secured for 2025 and 2026, the company is poised for continued expansion and success in the years to come. ANT Industries has global reach, with 72% of its products exported to international markets. Leveraging its stateof-the-art CNC machine shop, the company manufactures a diverse range of engine rings, casings, and prismatic parts for renowned aerospace customers, including Eaton Aerospace, Rolls-Royce, and ITP. Managing director Shaun Rowley commented: “We are immensely proud of the strides we have made as a company. Our success is testament to the dedication and hard work of our talented team, as well as our unwavering commitment to excellence in everything we do.” Central to ANT Industries’ success is its investment in cutting-edge technology and machinery. Over the past 18 months, the company has invested in new large 5-axis machines, including a Haas UMC 1000SS and an ANCA FX5 linear grinder, with additional investments slated for arrival in Q2 2024 through The Engineering Technology Group. ANT Industries also prides itself on its commitment to nurturing talent and fostering diversity within its long serving workforce. The company has seen success in hiring both young engineers and attracting more women to consider a career in the manufacturing industry and the company is dedicated to creating an inclusive and empowering workplace culture. “We remain steadfast in our commitment to driving innovation, delivering exceptional quality, and exceeding the expectations of our customers,” Mr Rowley concluded. “With the continued dedication of our team and our unwavering focus on excellence, we are confident that ANT Industries will continue to thrive and lead the way in precision engineering for years to come.” Q ANT Industries www.antindustries.com UK manufacturing leader and industrialist Philippa Glover has been appointed an Honorary Senior Fellow of Industrial Automation and Innovation at the University of Liverpool’s Virtual Engineering Centre (VEC). Ms Glover is a passionate advocate for the sector with an extensive track record of collaborating with industrial communities to address pressing issues that will shape its future and deliver inclusive economic growth. She has held senior roles across both multinational and SME manufacturing businesses. The VEC is an independent centre for industrial innovation and digital transformation based at the University of Liverpool, working with businesses and government to deliver digital transformation, effective policy and structural programmes supporting economic development and an industryled high-growth innovation ecosystem. Ms Glover’s appointment is a recognition of her substantial and sustained contributions as she embodies the university values and VEC’s ambitions. As part of her role, she will help to inform the development, delivery and integration of new partnerships and activities focusing on promoting UK manufacturing and the value of reindustrialisation for inclusive prosperity and economic growth. In 2022 she joined Liverpool Mayor Steve Rotheram’s Innovation Board, with a vision to contribute to shaping the region’s future by championing innovation, driving growth, and positioning Liverpool City region as a hub for cuttingedge solutions with an aim for increasing R&D spending to 5% of GVA by 2030. “To be awarded such a prestigious title from the University of Liverpool feels a huge privilege,” Ms Glover commented. “Institutions such as the University of Liverpool help to inspire, innovate, and drive positive change across the region and beyond. As a local resident, I look forward to using this award to support the University, its students, and the wider community to continue to develop the work they do to support and inspire our community and work towards delivering inclusive economic growth.” Andrew Borland, chief innovation officer of VEC added: “Philippa is a committed and creative industrial leader with a commitment to Liverpool City region and the UK manufacturing sector. We look forward to working with her to help develop a new generation of industrial innovation programmes and foster the next generation of industrial leaders.” The VEC is part of the Horizons project set up by Liverpool’s three universities and funded by the UK Government to help SMEs across the city region prosper. Q Horizons https://lcrhorizons.co.uk Philippa Glover appointed Honorary Senior Fellow at VEC University of Liverpool Philippa Glover, Honorary Senior Fellow at VEC University of Liverpool (left) with Andrew Borland, chief innovation officer at VEC ANT Industries produces an extensive range of components and assemblies for aerospace and gas turbine engines Aerospace specialist records best ever growth ANT Industries’ managing director Shaun Rowley
Doing the right things at the right time for the right reasons is what Mills CNC is all about. And, helps explains why we’ve recently become the exclusive distributor of Zayer bed, travelling-column and gantry-type horizontal milling machines in the UK and Ireland. Used extensively throughout Europe and the rest of the world by large component and mould tool manufacturers, Zayer machines are renowned for their power, precision, speed and reliability. They improve, and complement, our already impressive DN Solutions’machine tool portfolio perfectly, and enable us to provide customers with the most appropriate and effective machining solution…whatever the application. With business returning to pre-pandemic levels across many sectors, and with the need to improve productivity and process efficiency levels high on all manufacturers’agendas, we’ve now made selecting the right large-capacity machine tool in the future, much simpler and far more straightforward. Zayer machine tools from Mills CNC: You’re welcome! Call us now on 01926 736736or visit www.millscnc.co.ukfor details. Mills CNC: Like No-one Else! Zayer large-capacity bed, travelling-column and gantry-type horizontal milling machines: now available from Mills CNC. We’ve expanded our range and narrowed down your choice!
12 June 2024 Production Engineering Solutions pesmedia.com NEWS Want to win work in nuclear? # 0 ' - ҍ. Fit For Nuclear +-*"- (( # . # '+ #0) - . *! ( )0! /0- -. /* .. .. ) 1 '*+ /# $- + $'$/$ . !*- )0 ' - 0./*( -.ҁ * ! -҂ я Җ"- )/ *(+ )$ . # 1 - +*-/ /# / *0- .0++*-/ # . # '+ /# ( 2$) (*- /# ) ۆ эҁь $''$*) *! ) 2 *)/- /.ҁ # 1 )*2 )# ) ) 3+ ) /# я +-*"- (( ҂ 2$/# ) 2 .0++*-/ /* # '+ ( )0! /0- -. *! '' .$5 . /* 2$) 2*-& -*.. /# )0 ' - . /*-ҁ ) (- ҁ *ҁ0&Ҩ. -1$ .Ҩ!я) Inventory management solutions specialist, Tooling Intelligence, has formed a strategic partnership with the Howcroft Group, the two companies have announced. This collaboration will introduce a comprehensive inventory management programme to the Howcroft Group’s existing customer base, serving as a catalyst for further business growth. As a leader in delivering innovative inventory management solutions powered by SupplyPro, the Tooling Intelligence portfolio will enhance the customer supply chain for the Howcroft Group, an independent supplier of maintenance, repair and overhaul (MRO) consumables in South Yorkshire. This agreement marks a significant milestone for both companies, combining Tooling Intelligence’s cutting-edge technology with Howcroft Group’s expertise that has made the company a leading supplier of industrial supplies that includes bearings, electrical supplies, signage, tools, PPE and more. Together, the two companies aim to start a new era of streamlined inventory management solutions tailored to meet the needs of the Howcroft Group’s diverse customer base. Richard Swaffield, managing director of Tooling Intelligence commented: “We are thrilled to embark on this journey with the Howcroft Group. Collaborating with Allan Howcroft and his team presents an incredible opportunity to deploy our state-of-the-art inventory management solutions across various sectors. “The flexibility of our solutions perfectly matches the sheer breadth of the Howcroft Group product range while creating a flexible and easy-to-manage point of consumable collection for Howcroft customers. Offering this level of technologically advanced inventory management will deliver huge benefits to Howcroft customers in terms of inventory management and visibility, supply chain security, budgeting, reporting and much more.” Allan Howcroft, founder and CEO of the Howcroft Group, added: “We are proud to announce our partnership with Tooling Intelligence. It has been a fantastic journey exploring the capabilities and opportunities that Tooling Intelligence brings to the table. “Choosing Tooling Intelligence as our inventory management provider was a no-brainer. Their ability to provide tailored solutions that align perfectly with our vision and the needs of our clients was a primary deciding factor.” Q Tooling Intelligence www.toolingintelligence.co.uk L-R: Stuart Durham (Tooling Intelligence) Jake White and Allan Howcroft (Howcroft), Richard Swaffield (Tooling Intelligence), Luke Copcutt & Wayne Glynn (Howcroft) Tooling Intelligence signs partnership with Howcroft Group
pesmedia.com Production Engineering Solutions June 2024 13 NEWS Haas Automation | 01603 760539 | [email protected] Auto Parts Loaders | Plug & Play Robots | Integrated Pallet Pools NEW www.haas.co.uk MADE IN USA The world’s best selling 5-axis for a reason. A leading UK manufacturer of precision aerospace components has secured a string of new multi-million pound contracts – just a few days after it was named as a King’s Award for Enterprise winner for International Trade. Arrowsmith Engineering (Coventry), part of the ASG Group, has sealed longterm agreements with ITP Spain, Incora and Rolls-Royce in the UK and Germany, delivering the largest order book in its 57-year history. It marks what has been a strong export period for the business, with overseas sales rocketing by nearly 400% and accounting for 35% of the firm’s annual £8.3m turnover. Precision components manufactured at its Bayton Road factory in Coventry are sent to global customers in Brazil, China, France, Germany, Singapore, and Spain for end use in aerospace engines, landing gear and airframes. Jason Aldridge, managing director of Arrowsmith Engineering, commented: “It has been some week; from securing the International Trade title in the King’s Award for Enterprise on Monday to announcing our largest orderbook, underpinned by these landmark longterm agreements with some of the biggest names in aerospace. “Civil aviation – a major market for us – literally dropped off the cliff with the pandemic and we had to show good old-fashioned resilience and a fair bit of business innovation to get through it. But now we are back and targeting our bestever year of over £11m sales.” Arrowsmith Engineering, which has been reaccredited for the Silver SC21 supply chain award for quality and delivery performance, has just taken delivery of two twin spindle DN Solutions Lynx 21000ISLYA/B machines from Mills CNC. This £300K investment follows the success of three recently installed three Lynx machines and 5-axis DVF5000 and 4-axis DNM4500 cobot systems. Plans are now in place to take annual sales past £25 million over the next two years and this should result in the creation of a further 15 positions, with the focus on getting more women into engineering. Mr Aldridge added: “The King’s Award is fantastic news for our business and is testimony to how our staff have gone above and beyond to help us overcome the troubles of the pandemic and emerge even stronger.” Simon Weston, managing director of ASG Group, concluded: “ASG Arrowsmith operates to the highest world class manufacturing standards, and this is reinforced not only by the King’s Award, but the long-term customer agreements it has secured in the last week.” Q ASG Arrowsmith www.asg-group.co/arrowsmith Arrowsmith announces largest ever order book and King’s award
14 June 2024 Production Engineering Solutions pesmedia.com NEWS Birmingham-based precision stamping company, Brandauer, has completed a £3.25m investment drive to celebrate a King’s Award for Enterprise achievement. Brandauer, which employs 64 people at its Newtown factory, has just commissioned its fifth high-speed Yamada press that will help it deliver quick changeover subcontract stamping capabilities – ideal for clients requiring high speed, precision accuracy and multitool transfers. The installation follows the purchase of a laser microcutting machine, an investment that was made possible by a 40% grant from the Aerospace Up programme giving the business this technology for the first time. Together, the investments will drive up capacity to help Brandauer make the most of its new precision modular tooling concept that is promising to deliver up to £6m of domestic and international sales over the next two years. This involves the manufacture of globally competitive precision tools that can produce components for use in high specification construction applications, battery assemblies, MedTech devices and electrification amongst others. “It has been quite a week for the company, perhaps one of the proudest in our 162-year history,” explained Rowan Crozier, chief executive officer. “We’ve reinvented ourselves a lot since we started life manufacturing pen nibs and are now seen as one of the leading presswork and stamping specialists in the world, delivering micron accuracy components and precision tooling.” He continued: “The King’s Award for Innovation is such an important title for us and really opens new doors across the globe. This is the second royal award we have achieved, following our International Queen’s Award in 2019 – not many companies hold two titles simultaneously. “The initial award had already helped us win new contracts, especially in the US where the Royal Family are highly revered. I’m hoping the Innovation title will showcase our new precision modular tooling capability to new audiences and help us achieve our aim of delivering significant growth in this area over the next few years.” A significant amount of the knowledge generated from the modular tooling concept has been embedded into courses being delivered to OEMs, like JLR, at the Precision Tooling Academy in Aldridge, a joint venture between Brandauer and In-Comm Training. This will be used in courses that will help train the toolmakers of the future, a vital engineering discipline that was slowly dying out with specialists retiring without passing on knowledge and experience. Q Brandauer www.brandauer.co.uk Brandauer presses on with £3.25m investment ANCA, a leader in grinding technology, marked its 50th anniversary with an open house event at its UK branch. The event, which showcased a range of grinding technology innovations and celebrated the decades of partnership with manufacturers and partners, attracted over 80 visitors from across the UK and Ireland. The open house featured an array of topics highlighting the company’s latest innovations, including the AIMS automation system, the latest release of the cutting-edge ToolRoom software, and the Ultra technology for topquality tool production. Attendees also gained insights into micro tool manufacturing and single-setup tool manufacturing with integrated peel grinding, demonstrating ANCA’s commitment to providing comprehensive solutions to meet the evolving needs of manufacturers. The event’s agenda was filled with live machine demonstrations, informative presentations and celebratory activities, offering attendees a firsthand look at the latest technologies for precision tool manufacturing in action. In addition, ANCA collaborated with industry partners CemeCon (coating technology), GDS (clamping technology), Tyrolit (grinding wheels), and oelheld (fluid technology) to provide attendees with access to experts across the manufacturing process chain, enriching the overall experience. “We are thrilled to celebrate 50 years of innovation and success with our valued customers and partners,” said Neil Kendrick, operations manager at ANCA UK. “The open house event was an excellent opportunity for attendees to explore our latest advancements and gain valuable insights to enhance their businesses.” ANCA UK also announced a strategic partnership with GDS Präzisionszerspanungs from Ofterdingen, Germany. Under this partnership, ANCA will represent GDS in the UK and Ireland, bringing innovative clamping solutions and combined expertise to the market. Thomas Löhn, managing director at GDS said: “The open house was a perfect start for our partnership. Visitor feedback proved that there is a high demand for advanced clamping technology, like our new Shark or Hornet chucks, and the ANCA team is highly skilled and experienced.” Mr Kendrick added: “We are glad to have GDS onboard with their longstanding expertise and excellent product range. Our customer base relies on highquality products to guarantee the best solutions in quality and productivity, which we can provide even better now.” Q ANCA www.anca.com Boeing has expanded its presence in Bristol with a new 40,000ft² office, home to the company’s UK-based defence operations. Steve Burnell, managing director of Boeing Defence UK said: “Boeing’s presence in Bristol dates back more than two decades and our new, modernised facility, home to Boeing Defence UK, represents the next chapter of our history and presence in the local community where we are proud to live and work. “With over 2,100 people dedicated to our defence business in the UK, and 700 of these based in Bristol, the new facility will serve as a dynamic space for collaboration and innovation with our customers, colleagues and partners.” In Bristol, Boeing supports defence programmes for the British armed forces, including the UK’s Apache and Chinook helicopters, C-17 Globemaster, and P-8A Poseidon. It also assists the UK’s E-7 Wedgetail programme in Birmingham, where three Boeing 737s are being modified to become the future Airborne Early Warning and Control fleet for the Royal Air Force. Richard Murray, director air support at defence equipment and support (DE&S), the UK Ministry of Defence (MoD)’s procurement arm, added: “Driving UK prosperity and working closely with industry is essential to DE&S’ mission to equip and support our armed forces. Having Boeing Defence UK’s central hub so close to DE&S’ headquarters in Bristol is a welcome development and will further enhance the working relationship across the wide portfolio of Air, logistic information systems and training programmes we have.” Alongside employees carrying out research and development, engineering and business operations, a digitally skilled workforce supports the MoD’s logistics and engineering information systems programme. It is also home to the design and delivery of real and synthetic multi-domain training software and courses for UK defence platforms. Q Boeing www.boeing.co.uk Boeing opens new UK defence headquarters ANCA hosts open house to mark 50-year anniversary Scan here for more Boeing articles Scan here for more Brandauer articles
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16 June 2024 Production Engineering Solutions pesmedia.com MACHINING Operating from a 50,000ft² manufacturing facility, Dawnlough Precision was founded in 1987 and is accredited to ISO:9001, ISO:13485 and AS:9100D. Underpinning its growth is the adoption of advanced production tools such as FMEA, PPAP and SPC and investment in flexible, capable and productive machine tools. In fact, its production facility on the West Ireland coast has more than 54 CNC machines that provide premium manufacturing solutions. Recently acquired by the Acrotec Group, the 110-employee business is still run by longstanding managing director and previous owner Brian McKeon. Keith Kennedy, aerospace production manager at Dawnlough says: “We manufacture high precision components for the aerospace and Robotic Assisted Surgery (RAS) industries as well as tooling and production aids for the medical device sector. “When I started in 2006, tooling was the main business focus, but as the aerospace and medical device industries have expanded locally, this presented many opportunities. Our aerospace work started with seating components for Rockwell Collins, which led us into 5-axis machining. We then progressed to flight-critical components for the likes of Spirit Aero Systems and Pratt & Whitney. Similarly, we evolved from manufacturing medical tooling and instruments to producing complete assemblies.” Discussing the expansion in the medical industry, Mr Kennedy continues: “Our core business has predominantly focused on vascular work and from this, we have expanded our offering. We now produce an array of components for our RAS customers as well as consumable instruments.” The first Bumotec on the Emerald Isle It is here that the search for a suitable machine led Dawnlough to purchase a Bumotec 191neo FTL-R in June 2022. Discussing the acquisition, Mr Kennedy recalls: “We had several components we initially targeted for this type of machine. “We needed a machine with very high levels of accuracy, short cycle times and high efficiency because it’s a very competitive market. We visited many companies reviewing high-accuracy machines, but it’s only as you look closer and purchase one of these machines for this type of work, you really see the value-add they bring. “We were looking for repeatability, flexibility, high spindle speeds, the ability to machine hard material and 2-3μm precision on production runs. We had very specific requirements and we were not sure if it was going to be achievable. “Some of our initial trial parts were 46HRC and we are using tools from 0.1 to 0.5mm. We needed repeatability of 2 to 3μm, but we needed to hold that overnight. Some of the functions of the Bumotec machine such as the software for monitoring the machine, the cutting load, the contact cutting time and the large 90 tool ATC in the machine are incredible. It was a huge investment and an unknown risk – but it ticked all the right boxes.” As well as machining 46HRC parts, there was also a need for specific RAS components that were a key driver behind the first Bumotec installation: “We were machining these parts in batches of 200-off up to six times a year and there are six different parts in the family with a projected ramp-up of 200-300% a year so we wouldn’t have been able to support the customer with our existing method,” Mr Kennedy explains. “There was also a fallout due to accuracy, as we couldn’t 100% meet the GDT accuracy. “We needed to put bar diameters up to 1.5 inches in the machine while also running high precision production runs of small instrumentation parts. The Bumotec also had the subspindle and a robotic unit which was important, as we need traceability for every part we make. We took demonstration parts to Bumotec in Switzerland in April 2022 and we received the machine in June.” Success brings machine number two Following the success of the Bumotec 191neo with FTL-R configuration, the Galway company then added a second Bumotec 191neo in March 2023. Supplied with an FTLPRM configuration, the second machine was introduced with complete automation and a 20-position pallet station for lights-out production. “What they offered us with the second machine was a complete turnkey solution for our instrumentation components. We had given them a target for extreme levels of precision and production volume with the flexibility to produce families of parts,” Mr Kennedy recalls. “We needed to machine materials from 46 to 52HRC such as 17-4 and 420 stainless steel as well as titanium. The instrument parts for use in invasive robotic surgery include tools like grippers, cutting instruments and scissors. We are producing the parts in medium to high volume runs across two different parts in various quantities per month.” Some of the parts had very long cycle times on the 5-axis machines and this needed to be reduced to below 30 minutes with 48HRC material. Not only was the cycle time a challenge, but Dawnlough had to attain precision levels in a production environment with the flexibility to produce upwards of 30 different components. Initially machining 20 to 50 parts a month, the schedule was set to rise rapidly to 200 parts per month before reaching production volumes – numbers not possible on a 5-axis machining centre. “With the second machine, we knew exactly what Bumotec could offer, so we worked with them remotely,” Mr Kennedy says. “What Bumotec offer is exceptional and way beyond anything we had anticipated. With the original Bumotec 191neo FTL-R, we had the subspindle, but with the next set of parts we needed the Bumotec 191neo FTL-PRM. With this machine, we had the option of the vice, a 3m bar feed and also a robot loader. We needed the robot loader for traceability. It also expanded the capacity of the machine where we could go from 50mm barfed stock to 80mm billet loading. “The sub-spindle option we had on the FTL-R wasn’t feasible for the parts we needed, whereas the FTL-PRM gave us two vices which negated secondary machining, so to be able to pick up the component in the vice and conduct the second operation in a single cycle was key to finishing the parts.” Contributing to the conversation, Dawnlough’s general manager, Eddie McHugh adds: “We were machining parts on our 5-axis machining centres and we needed to increase output by 400%. We were machining around 400 parts a month on two different products with a cycle time of 45 minutes. This was tying up two machines and one man permanently every month. On second and third shifts with fewer staff, we had concerns about machine tolerance drift, so output was reduced and it also made inspection labour intensive. “With the arrival of the Bumotec 191neo FTL-PRM there’s a labour saving with one man running two machines around the clock. Additionally, with the pallet loader, the parts are loaded into the machine and back to the pallet loader in a specific order which made huge savings on inspection. We have also made considerable savings on tool costs and changeovers Bumotec solves medical production puzzle Galway-based Dawnlough Precision is a subcontract manufacturing business that has travelled a relentless journey of growth since it started manufacturing tooling for the aerospace and medical industries back at the start of the millennium. Instrumental to this success is investment in two Bumotec 191neo turn/mill centres from Starrag. PES reports. The Dawnlough facility in Galway, Ireland Keith Kennedy (left) With senior CNC engineer Ronan Faherty A selection of intricate medical device components produced on the Bumotec S191neo at Dawnlough
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