Niche benefits

One of the advantages of operating in a niche market is that it can offer a degree of stability during difficult times and this is certainly true of Tunbridge Wells, Kent-based

gear cutting specialist, Muffett Gears. After more than 80 years in the business, the company knows a thing or two about running a successful operation. Dave Tudor reports.
The dark days of 2009 affected just about every company imaginable but through offering a range of specialised services to a diverse customer base, Muffett managed to maintain healthy business levels, particularly in the medical sector where it has been a major player for years. Indeed, according to managing director Tony Smith, business is now back to pre-recession levels. Gear cutting is one of those disciplines that traditional subcontractors tend to give a wide berth. In common with other specialist niches like deep hole drilling, the equipment is phenomenally expensive when compared to conventional machine tools and finding staff with the required skill levels to carry out the often very intricate work is somewhat challenging to say the least. A traditional family run business employing 38 people, AS9100 accredited Muffett Gears is jointly owned by Mr Smith and his sister Judith. The siblings' grandfather Stanley Muffett way back in 1920 decided to make the positive step into gear manufacturing – recognising the fact that even then, there were very few companies around doing this type of work. The Second World War brought an influx of new business for Muffett – one of its biggest customers was the MoD – and this continued for many years afterwards. Muffett's roots are still firmly anchored in gear cutting but today the company has many more strings to its bow including milling, turning, grinding and assembly work. The company is synonymous with the manufacture of spur, helical and bevel gears and racks, worms and worm wheels and consequently often finds itself getting involved with customers at the design stage of projects, drawing on its considerable experience to offer support and advice prior to manufacturing taking place. 85% of Muffett's business is concerned with the manufacture of customised components but it also can supply standard range of standardised gears and gearboxes off the shelf. Machine mix Mr Smith believes that an ongoing programme of investment has helped keep the company healthy and profitable. Muffett gained AS9100 registration at the back end of 2009 and this is complemented by a constant review of machine tools and equipment. “The equipment on our shopfloor is a real mixture of old and new machines,” he reveals. “On the gear cutting side, some of our hobbing and shaping machines are fifty years old but because we've maintained them regularly and looked after them they still produce work of excellent quality. “This year however, we've invested £375,000 in new machine tools to complement our gear cutting activities. This comprised a CMZ TL15 TM lathe with driven tooling – our second CMZ machine – a Mori Seiki NV5000 machining centre and a Tornos Gamma 20/6 sliding head lathe. “The new Mori Seiki NV5000 is the second machine of this type we have installed,” he continues. “The machine is fitted with a Chick indexer system supplied by 1st MTA/ Kitigawa which will machine eight gearbox cases in each cycle with cutting tools supplied by Matrix Tooling. The machine is also fitted with Renishaw probing for in process gauging and to check that parts are fixture correctly. The control system is latest adopted by Mori Seiki and will enable us to machine considerably quicker than on the earlier NV5000. Purchasing priorities There is a number of Mori Seiki machining centres adorning the shopfloor at Muffett. Mr Smith is clearly a fan of the Japanese manufacturer's equipment. “We enjoy an excellent relationship with Mori,” he divulges. “There are many fantastic machine tools available on the market but for us it's the levels of service, support and engineering expertise that we get from Mori that makes the real difference. We could have bought a machine for half the price but in the long run it really is false economy. Importantly, our operators really like Mori Seiki machines and see no reason to change.” Indeed one machine on the shop floor – a Mori Seiki NL lathe has actually been modified to carry out gear hobbing operations. “It's a system designed by Mori Seiki as part of its Polygon turning programme,” advises Mr Smith. “Whilst combining machining processes on a single machine has limitations, in certain applications it has real benefits.” But the investment plans don't stop at machine tools. Muffett operates an ongoing programme whereby it's older gear cutting machines are gradually being refurbished with 2-axis CNC operation and controls. In addition, the company will be focusing heavily in the months to come on purchasing new specialised gear cutting equipment from manufacturers such as Gleason, Liebherr and Mitsubishi. It's a policy that has served the company well. This year, Mr Smith anticipates that turnover will hit the £4 million mark. “Selecting the right gear cutting equipment takes a bit more homework,” he reveals. “Typical pricing starts at around the £250,000 mark so getting it wrong can prove to be very expensive. At the moment we're looking at investing in a new CNC gear shaping machine so we'll be making a purchase in the near future.” Big on branding Muffett is a company that has always taken its marketing and branding seriously and consequently – unlike some other subcontractors – it sees carefully selected exhibitions and events as an ideal vehicle for showcasing its capabilities. “Exhibiting at shows works for us but I can see why some subcontracting companies don't see it as value for money,” Mr Smith affirms. “At the end of the day, subcontractors predominantly provide a service rather than a product and this can be difficult to convey on a stand at a show, but we exhibited at Farnborough this year as well as the recent Aero Engineering event held at the NEC and both proved to be excellent in terms of lead generation and enquiries. We've already booked up to exhibit at next years Aero Engineering show.” People power As it becomes ever more difficult to recruit staff of the required calibre in the marketplace, Muffett relies heavily on a proven apprenticeship scheme to nurture new talent through the ranks. Currently there are three apprentices employed with a further two waiting in the wings ready to make a start in the next few months. “I believe the face of engineering is slowly changing for the better,” Mr Smith states. “In our experience young people are starting to realise that engineering can be an exciting and rewarding career and this is reflected by the responses we get when we're looking to take on new apprentices. The prosperity of manufacturing is vital for the prosperity of the country as a whole and we'll continue to encourage new blood into the company as we have done since day one.” It's a philosophy that brings results. The average length of service of a Muffett employee is a staggering 25 years. “Our people are our greatest asset.” Mr Smith enthuses, “and we totally appreciate their loyalty and commitment.” And indeed he does. When financial targets and objectives are met, Mr Smith rewards his staff via a company bonus scheme. “Achievement and success relies on everyone pulling together collectively,” he explains, “and every person in the company plays his or her part. When we're doing well I make sure that everyone benefits and feels part of the success.” Muffett Gears
www.muffettgears.co.uk

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