Knowledge is power

Subcontract engineering companies tend to fall into two distinct camps. Some offer a diverse range of services so that perspective customers can get everything they need under one roof whilst others stick to their core skills and become specialists – highly skilled in their chosen field. For Midlands-based Subcon Laser, the clue is definitely in the company name writes Dave Tudor.

Originally started (and still owned today) by Bill and Christine Brown in 1989, Subcon Laser will be celebrating its 25th birthday next year. Whilst its expertise, pedigree and hard earned experience is undoubtedly centred around laser cutting, the company also offers a range of additional services including bending and forming, assembly, welding and assembly, machining, presswork, plating and powder coating, vibratory deburring, drilling and tapping, and reverse engineering. It employs 25 members of staff and operates from a 60,000ft² facility in Nuneaton.

“Our raison d'etre is definitely laser cutting but some of our customers need ‘finished' product,” explains Tom Mongan, Subcon Laser's general manager. “In those instances, we have a tried and trusted network of partners that we can call upon and we can manage the whole process for the customer. It's not our intention to become all things to all men however,” he adds. “Laser cutting remains our core skill and we don't want to potentially distance ourselves from our customer base through offering services that they may already undertake themselves such as subcontract machining. We don't want our customers seeing us as competitors.”

Pushing the boundaries

Subcon Laser offers both 2D (2-axis) and 3D (5-axis) laser cutting services and even today Mr Mongan believes that 3D laser cutting is a skilled discipline that differentiates it somewhat from the competition – particularly with its many customers in the automotive sector. “We're certainly not the only company that offers it but I wouldn't say it's widely available,” he affirms. “We embraced it back in the late 1990s when using a multi-axis head on a laser cutting machine to produce often highly intricate work was a relatively new concept. The decision to buy a 5-axis laser cutting machine back then was entirely customer driven – and importantly the technology was mature and reliable enough to warrant the investment. It remains an essential part of our service offering today.”

Just as 5-axis machining has emerged strongly in recent times in the machine tool world, 3D laser cutting is pushing the technological boundaries in terms of the types of parts that can be processed. Mr Mongan says an ideal application is with pressed parts in low to mid volumes. “With 3D laser cutting, the laser beam, rather than being restrained by rigid X- and Y-axis linear movement, can move around a particular form or up and over a part,” he reveals. “It's also a cost-effective process because it effectively negates the need for expensive tooling. All that's required is a fixture to hold the workpiece.”
Interestingly, whilst the lion's share of materials processed by Subcon Laser is mild steel, stainless and aluminium, the company is seeing healthy growth with non-metallics such as ABS, acrylic and plastic where the inherent accuracy and good surface finish provided by laser cutting is particularly effective.

Well-equipped

Equipment-wise, Subcon Laser uses Trumpf machines almost exclusively. In its 2-axis armoury it makes effective use of a Trumpf TruLaser 5040 with 6kW laser and a bed size of 4m by 2m; a Trumpf Trumatic 3050 with 5kW laser and 3m by 1.5m bed; and a Laser Lab Profile with 3m by 1.5m bed and 1.7kW laser.

On the 5-axis front, the company has three machines at its disposal: two Trumpf LaserCell 1005 machines with bed sizes of 3m x 1.5m. One machine incorporates a 5kW laser whilst the other utilises a 2.4kW variant. Completing the 5-axis portfolio is a Trumpf TruLaser Cell 7040 with 4m by 1.5m bed and 4kW laser.

“We use Trumpf machines because they're both powerful and user-friendly,” Mr Mongan explains. “However we have used Bystronic and other manufacturers' machines in the past and they're very good. Whenever the need arises to purchase a new machine (historically around every three years on average) we'll always thoroughly evaluate our options – we have no desire to tie ourselves to one manufacturer.”

In laser cutting circles, fibre laser machines are a topical talking point at the moment and Subcon Laser is currently considering its options in this department. As Mr Mongan reveals however, there's good reason why the company hasn't rushed out and bought a new machine: “Fibre lasers are excellent for cutting materials up to around 5mm thick but the work we undertake is so diverse – we can cut anything from 0.5mm to 25mm thick steel plate – we have to question whether it would be money well spent?” He continues: “Currently, only 15-20% of the work we undertake could be processed on a fibre laser machine, but the inherent speed advantages that the technology brings could make it worth investing in. One thing we'd need to look at carefully is what happens when fibre machines break down? As the technology is relatively new, little is known about the cost of replacement parts and servicing. All this would need to be taken into consideration.”

Staff matters

Despite the well-documented skill shortage that is predictably causing many manufacturing companies a rather large headache at the moment, Subcon Laser has not only been able to retain its valued members of staff over the years, but has also recruited two trainees and a telesales person in the last six months.

“We rely very heavily on our staff – they're our greatest asset – so our recruitment process is very methodical,” Mr Mongan advises. “We operate a three shift system and the bottom line is that if an operator decides not to turn up for work it impacts not only on the company but also on the customer. It's a very competitive marketplace out there and working together effectively as a team is essential. Fortunately, this is an area where we really excel and our staff retention levels are amongst the best in the industry.”

Because of the versatility laser cutting as a process provides, Subcon Laser has built up a pretty diverse customer base over the years operating in an equally diverse span of industries encompassing everything from rail transport and marine through to shopfitting and agricultural. The precise, controlled nature of the process also lends itself well to artistic projects and particularly worthy of note for Subcon Laser was its involvement in manufacture of a highly ornate statue for the cycling events at the London Olympics. Further illustrating the company's versatility is its involvement from the outset in manufacturing parts for a pizza making oven machine!

Jewel in the crown

Nearly 25 years is a long time to be in business and Mr Mongan believes Subcon Laser's success is down to two main elements: “I think the fact that we're not afraid to invest in new technology has contributed significantly to our longevity but in my mind it's the skill and expertise of our staff that's the real jewel in the crown,” he enthuses. “Aside from the three new recruits that we employed recently, the average length of employee service is 12 years. You simply can't buy that level of knowledge and experience and all this is reflected in the service we can offer customers.

“At the end of the day anyone can pay lip service to providing a good service and anyone can go out and buy the latest machines and equipment. What makes us different is the experience, skill and expertise of our staff and our willingness to go the extra mile for our customers.”

Subcon Laser
www.subconlaser.co.uk