New subcontract machining operation invests in Doosan multi-tasking machines

To help get its recently introduced precision subcontract machining operation up and running, and to give it a competitive edge, Greater Manchester-based, Volz Engineering has invested in two, new multi-tasking Doosan machines, each supplied with integrated automation, from Mills CNC.

Volz Engineering is part of the Volz Group and a wholly-owned subsidiary of Volz Filters UK. The parent group employs around 340 people worldwide and is headquartered in Deilingen, Germany. It has developed a strong global dealer network and is a renowned manufacturer of tube fittings, hose connections and balls for ball valves. Located in Manchester, Volz Filters is a manufacturer of filter products and filtration media.

The two Doosan investments undertaken by Volz Engineering are both Fanuc-controlled multi-tasking machine tools: a compact 8” chuck Lynx 2100LSY turning centre, equipped with a sub-spindle, Y-axis and driven tooling, and a DVF 5000 5-axis machining centre with a 18,000rpm spindle and a 120-tool position ATC. The machines were installed at the company’s 10,000ft² facility in Rochdale in December 2021 and February 2022 respectively.

To increase the productivity potential of each multi-axis machine, Volz Engineering, through discussions with technical sales staff at Mills CNC, augmented its investment by placing orders for a Hydrafeed Multifeed 65 short magazine bar loader (to be integrated with the Lynx lathe), and a Doosan (eight-pallet station) Automatic Workpiece Changer (AWC) for the DVF 5000.

“As part of our ambitious growth strategy we have recently rationalised and refocused the scope and scale of our operations: divesting low-growth and less profitable business activities in favour of ones that offer a better growth trajectory and a more favourable return on investment.” says Volz Engineering’s managing director, Alan Reeson.

As a consequence, Volz Engineering’s focus, moving forwards, will continue to be on the manufacture of high-quality components such as filter frames and strips for its parent company, as well as on the design, development and manufacture of specialised, application-specific automated filtration production machines.

To meet global demand, it is anticipated that the company will significantly ramp up production of these machines in the future.

In addition to focusing on these core business activities, the company has also made the strategic decision to diversify its operations and create a high-quality, precision subcontract machining operation located at its existing facility. Alan Reeson believes this is where the real opportunity for significant and sustained business growth lies.

The new venture

Volz Engineering’s precision subcontract machining business is intended, in the first instance, to provide local, regional and national manufacturers with high-quality machined and competitively priced components.

“The danger, when setting up any subcontract machining operation, is to lack focus and attempt to try and be all things to all people,” Mr Reeson affirms. “This approach invariably means that you can end up chasing your tail and are tied up dealing with unprofitable work.

“For our operation we have adopted a different route and implemented a ‘sniper’ strategy, targeting those sectors and specific companies where we know we can provide real value and develop long-term, mutually profitable relationships.”

Doing the homework

Prior to launching its new precision subcontract machining operation, the company did its homework and spent significant time and resources creating a robust and comprehensive business plan.

“By researching the market and understanding customer needs and requirements, as well as competitor strengths and weaknesses, we have been able to create differentiation in the market based on quality, service and reliability, and cost-competitiveness,” Mr Reeson says.

The scope and scale of Volz Engineering’s subcontract machining operations determined in part by its market research activities and combined with the significant experience and expertise of key members of staff, are focused on the milling and turning of complex, precision parts made from a range of materials, and characterised by their tight geometric tolerances and high surface finish requirements. Specifically, the focus is on milled parts with typical dimensions up to 500mm x 500mm and turned parts with diameters up to 65mm.

“Like every company we have limited space available. In setting up our subcontract machining operation we clearly had to keep in mind these limitations as well as the footprints of the new equipment we required,” adds operations director James Alletson.

“Another aspect of our subcontract service was on our ability to machine one-offs and prototypes, through to pre-production parts and low-to-medium volume batch series.”

Getting started

Having identified where the business opportunities existed, Volz Engineering implemented an action plan to bring the new venture to life.

The plan included a programme to refurbish and modernise its existing facility (in order to comfortably house the subcontract machining operation), as well as an outline CAPEX budget that would be used to acquire the new machining technologies and equipment required.

“Our facility needed to be significantly upgraded in order to meet our immediate and future needs. In addition to improving the power and air supply and overhead lighting, we also spent time reorganising the factory floor to optimise the workspace available and to improve workflow,” Mr Alletson explains.

“Creating dedicated zones for filter component production and for the design and assembly of our specialised automated filtration production machines freed-up much needed space for the new subcontract machining operation.”

The success of Volz Engineering’s subcontract machining operation depended on its ability to make complex, precision parts faster, better and more economically than the competition.

In order to do this the company made a number of strategic investment decisions.

It was decided, early on in the process by senior managers that the subcontract service would have and rely on new, as opposed to used, machine tools and equipment.

“Whilst there are no doubt some excellent used machine tools on the market, we decided, from a reliability and performance perspective, that our new precision subcontract service would have new machines and equipment at its disposal,” Mr Alletson asserts.

“Because we want to break into, consolidate and grow our position in advanced, hig-tech markets such as automotive, aerospace, and defence, it was important from the outset that we created a favourable impression with customers.

“New machines don’t just look the part; they are also less prone to breakdowns, inspire confidence with customers that you can meet their expectations, and signify to internal staff the commitment to the new venture.”

Deciding on Doosan

Senior managers at Volz Engineering decided early on in the process that the new machine tools they wanted for the subcontract machining operation would be Doosan.

“A number of staff had gained experience operating and programming Doosan machine tools from previous employment. They liked the machines, were familiar with the controls and the machines’ layout and configuration, and also recognised and appreciated the strength of the pre-and aftersales service and support provided by Mills CNC,” says Mr Alletson.

Volz Engineering made the decision to invest in multi-axis, multi-tasking machines. The 8” chuck/65mm bar diameter Lynx 2100LSY, with its 300mm maximum turning diameter and 510mm maximum turning length, is equipped with a 15kW/4,500rpm spindle and a 12-station turret. With up to 36m/minute rapids, 6,000rpm driven tooling capability, 105mm Y-axis and a 5”chuck 6,000rpm sub-spindle, the machine is fast, and flexible.

The DVF 5000 5-axis machining centre is equally versatile and productive and is equipped with an 18,000rpm spindle and a 120 position ATC. The machine features integrated thermal compensation, 40m/minute rapid rates and has a 500mm diameter table with a 400kg maximum table load.

Explains James Alletson: “Multi-axis and multi-tasking machines, like the Lynx 2100LSY and DVF 5000 are critically important if you want to reduce set-up and part cycle times. The ability to machine parts to completion in a single set up improves productivity and operational efficiencies and delivers a real competitive advantage.”

Integrated automation vs standalone

Right from the outset, the focus for Volz Engineering was to optimise the new machines by investing in automation systems which would help improve operational efficiencies, reduce the cost per part and enable tight lead-times to be fulfilled.

“We recognised that an ability to run the machines unattended, overnight and over the weekends, would give us a distinct competitive advantage over many of our competitors,” Alan Reeson recalls. “There seemed little point in making the investment only to have them sitting idle for a considerable period of time every week.”

Since being installed the two new Doosan machines have been working well.

In just a few months almost the entire turning capacity provided by the Lynx 2100LSY investment has been taken by an automotive customer. This has resulted in the company making an investment in a second multi-tasking Lynx lathe – a larger 10” chuck Lynx 2600SY and a MSV 80 bar feeder.

Says Mr Reeson: “The Lynx 2100LSY is fast, accurate and versatile – a productivity powerhouse. The machine and integrated bar feeder enables continuous production and has helped us to win significant new business in a relatively short space of time.

“It’s a similar story with the DVF 5000 and integrated AWC. It’s equipped with a powerful spindle, a large ATC, Renishaw probing, thermal compensation and an efficient swarf management system. With the eight-station workpiece pallet changer, it’s built for reliable unattended, lights out operation and is proving instrumental in helping us make serious inroads into the aerospace and defence component manufacturing markets.”

Volz Engineering
www.voltzfilters.com

Mills CNC
www.millscnc.co.uk

Company

MIlls CNC

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