PES Media Production Engineering Solutions January 2024 pesmedia.com R E Thompson: leading the charge in engineering innovation Pages 52-53 Investing today for a smarter tomorrow Machined Components: pages 52-58 SUBCONTRACTING SOLUTIONS ukmfgnews Preview pages 35-45
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www.pesmedia.com Production Engineering Solutions January 2024 3 Happy New Year! And now allow me to rewind a tad. November and December last year, as is the norm, proved to be absolutely manic with open houses. Team PES managed to attend most of them I think: Star GB; Grob; Hurco; Amada; Mazak; Ceratizit; and Axe & Status. All were very well attended, fantastically organised and brimming with technology. It’s easy to overlook the humble open house, but in recent years they’ve evolved into an absolutely invaluable platform for networking and showcasing new products. And there’s a social element which also can’t be underestimated. Let’s face it, it’s just really nice to be able to catch up with friends and colleagues in the industry. The relationships between suppliers and customers are often forged over many years – which got me thinking about the old adage ‘people buy from people’ and what underpins its importance in the business world. It’s a timeless phrase that encapsulates a fundamental truth about the human element in business transactions. At its core, it underscores the importance of personal relationships and trust in the buying process. In a sector often dominated by technical specifications and quantitative metrics, the human connection becomes a crucial differentiator. A warning – I’m going to go a bit Sigmund Freudesque here. The psychology behind this concept is rooted in the basic human need for connection and trust. When customers make a purchase, especially in fields like manufacturing and engineering where the stakes (and money) are high and the products complex, they are not just buying a product or a service; they are buying into a relationship. This relationship is built on trust, understanding, and the belief that the seller has the buyer’s best interests at heart. It’s a psychological contract that goes beyond the physical product. Trust, in this context, is multi-dimensional. It involves trust in the seller’s expertise, trust in the product’s quality and reliability, and trust in the aftersales service and support. When a customer interacts with a person rather than a faceless entity, they are able to gauge sincerity, competence, and authenticity more effectively. Personal interactions provide the subtleties of non-verbal communication – the tone of voice, body language, and eye contact – which are critical in building and maintaining trust. Moreover, in manufacturing and engineering, where products are often custom-made or highly technical, the sales process is often consultative. The seller’s role morphs into that of an advisor or consultant, rather than just a vendor. This approach fosters a deeper understanding of the customer’s unique needs and challenges, leading to more tailored solutions and, consequently, higher customer satisfaction. I think what I’m trying to say here is that in a world of shops disappearing from the High Streets, autocheckouts in supermarkets, faceless doctors’ surgeries where we view getting an appointment with a real doctor as a personal triumph, post offices becoming as rare as hens’ teeth and banks vanishing at an alarming rate, proper, real human interaction in my mind, particularly in business, is more important than ever . Don’t get me wrong, I love technology and the ways it has enriched our lives and made many things so much easier – but I like talking and dealing with real people as well, particularly if I’m buying something that needs careful consideration and a thorough evaluation process before parting with my hard-earned cash. Long live open houses! Dave Tudor Editorial Director The undeniably strong correlation between successful manufacturing companies and their willingness to invest in people and technology has been proven time and again. On the back of a recent £2.2m+ investment in its manufacturing capabilities, this philosophy is at the core of Hampshire-based precision subcontractor R E Thompson’s modus operandi. Dave Tudor reports. See pages 52-53 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. No part of this publication may be reproduced or transmitted without the consent of the publisher. © MIT Publishing Limited 2023 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 27 Issue 332 ISSN 1460-3926 EVENTS January 2024 TCT Japan Tokyo Big Sight, Japan 31 Jan - 2 Feb 2024 February 2024 Southern Manufacturing 2024 Farnborough, UK 6-8 February 2024 April 2024 MACH 2024 NEC, Birmingham, UK 15-19 April 2024 April 2024 CONTROL 2024 Stuttgart, Germany 23-26 April 2024 5 Alloy Wire heads for record year after management buyout Reprieve for UK carmakers over EVs and batteries NEWS MACHINING 20 Grob unveils state-of-the art showroom in Stratford A class act 5-AXIS 26 Stepping up with 5-axis EDM 29 New Sodick wire eroder enhances precision and productivity TOOLING 30 Building business with a strong tooling partnership The path to better hole making in aluminium SOUTHERN MANUFACTURING 2024 35 Southern Manufacturing & Electronics is more popular than ever QUALITY & INSPECTION 47 To scan or not to scan? AUTOMATION & ROBOTICS 49 New 5-axis machining centre is automation-ready Fastems’ new modular FPS is a perfect fit Circulation Perception SAS Phone: 01825 701520 pes@mitpublishing.com Publisher David Rose Editorial Director Dave Tudor T: 01634 825702 newsdesk@pesmag.co.uk Deputy Editor Ed Hill T: 01634 825705 ehill@mitpublishing.co.uk Production Coordinator Ewa Hodden T: 01634 825703 ehodden@mitpublishing. co.uk Digital Content Coordinator Michael Tyrrell mtyrrell@mitpublishing. co.uk Financial Controller Valerie Prentice accounts@mitpublishing.co.uk Sales Manager Tammy Jukes T: 01634 825706 tjukes@pesmag.co.uk Sales Director Andy Morley T: 01634 825701 amorley@pesmag.co.uk Contacts
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, sales@hurco.co.uk, service@hurco.co.uk 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 See us at Southern Manufacturing and Electronics 6th-8th February 2024
pesmedia.com Production Engineering Solutions January 2024 5 NEWS COMPANY FINDER Acorn Support 5 Addmore Engineering 30 ADS Laser Cutting 10 Alloy Wire International 5 Altair 14 BAE Systems 6 BDO 5 Black Hills Products 10 BTMA 57 Cast Metals Federation 17 Ceratizit UK & Ireland 30 Citizen Machinery 54 Cranden Diamond 29 DMG Mori UK 49 Dugard 55 EngineeringUK 12 Expert Technologies Group 50 FANUC 13 Fastems 50 Grob Machine Tools 20 Guhring 32 Heller Machine Tools 12 Hurco 18, 26 Mach Machine Tools 22 MTA 6 Mills CNC 24 Mitsubishi Materials 32 NETA Training Group 22 Nissan 12 Optimax 47 R E Thompson 52 Reginson Engineering 54 Sandvik Coromant 31 Sheffield Forgemasters 14 SMMT 10 Sodi-Tech EDM 29 Southern Manufacturing & Electronics 35 Tenable Screw 57 UK Battery Industrialisation Centre 9 Walter Tools 12 Yamazaki Mazak 17 EDITORIAL ADVERTISING 1st Machine Tool Accessories 19 Blum-Novotest 39 Bowers Group 48 Ceratizit UK & Ireland 60 Citizen Machinery 8 Colchester Machine Tool Solutions 16 Compass Business Finance 6 Engineering Supply Chain Show 46 Filtration Service Engineering 15 Grenville Engineering 40 Grob Machine Tools 21 Guhring 42 Haas 13 Heller Machine Tools 27 Hurco 4 Iscar 33 J&S Engineering 9 Kyocera SGS 31 Lang Technik 49 MIE Solutions 41 Mills CNC 7 Mini Gears 22 Mintdale Precision Engineering 43 Mitsubishi Materials 11 Muffett Engineering 57 NCMT 23 NJ Metrology 47 Plastic Turned Parts 53 Qualiturn Products 58 Renishaw 51 RK International 37 Sodi-Tech EDM 28 Southern Manufacturing & Electronics 38 Subcon Drilling 54 Swissmatic 56 Thame Workholding 5, 44 Vision Engineering 36 Wallwork Heat Treatment 45 Warwick Machine Tools 29 WH-Lead 26 XYZ Machine Tools 2 Yamazaki Mazak 34 NEWS Scan here for more Alloy Wire International articles One of the UK’s leading manufacturers of round, flat and profile wire is on course to celebrate a record year – less than 12 months on from a management buyout (MBO) designed to protect the values of the business. Alloy Wire International (AWI), which was formed in the Black Country more than 77 years ago, has seen sales rocket by £3m since the deal was completed in January, taking turnover to £18m with the prospect of it breaking £20m in 2024. Demand from customers in more than 63 countries has been behind the initial boost, but the new chairman Mark Venables is adamant that the firm’s commitment to extending the employeeownership of the company – and the culture this brings with it – will drive the ongoing success. Company management took the decision two years ago to look for the future owners from within, with long-term staff members Tom Mander, Adam Shaw and Andrew Du Plessis leading the successful MBO. A complex process was made easier by expert advice from Dudley-based Acorn Support, which provided an external sounding board for the decision-making and put in place psychometric testing to identify key personalities, emotional behaviour traits and ability to work in a team. Mr Venables said: “We knew we had some very talented individuals in the business, and it was always our gut feeling that the next owners would come from within. The work we did with Acorn gave us a clear insight into future roles and the confidence that Tom, Adam and Andrew had the necessary skills, personalities and characters to make it work. “This accelerated succession planning and led to the MBO which has proved an overwhelming success. Alloy Wire International is in very safe hands and, importantly, has a management team in place that has new ideas and new innovations that will continue to facilitate our growth, while also staying true to our employee-owned culture that has governed the last 77 years.” Q Alloy Wire International www.alloywire.com Q Acorn Support www.acornsupport.co.uk L-R: Andrew Du Plessis, Adam Shaw, Tom Mander and Mark Venables Alloy Wire heads for record year after management buyout The proposal from the EU Commission to extend the current rules of origin for electric vehicles and batteries until 31st December 2026 will be a big relief to UK car manufacturers, according to accountancy and business advisory firm BDO. Matthew Clark, international trade partner at BDO said: “The automotive sector in the UK has faced numerous challenges in recent years. Brexit, COVID and the resulting supply chain shocks and interest rate rises have made life very difficult for the UK’s carmakers, but there has been a slew of good news in recent weeks. “The confirmation at the Autumn Statement that full expensing would be made permanent has been warmly welcomed by the sector and should provide automotive businesses with more certainty to enable them to make long term investment decisions. “Nissan’s announcement just days later that it would invest up to £1.12bn in its UK operations provided a further boost to the prospects for the UK’s car manufacturers and their domestic suppliers. And this week’s news that the EU Commission is proposing an extension to the current exemptions regarding the rules of origin is the icing on the cake. “Since coming into force in January 2021, companies have had to demonstrate the originating status of goods – namely cars and their components – traded with the EU, in order to be entitled to preferential treatment under the Trade and Cooperation Agreement. “However, there was a built-in exemption from the 10% import duty for electric car batteries which was due to expire on 31st December 2023. Had this not been extended, it would have been more expensive for UK manufacturers to export to its main EU markets and would have likely raised prices for EV buyers. “Extending this exemption until 31st December 2026 will give UK and EU manufacturers some important breathing space which should allow them to ramp up domestic production capacity. “However, the EU has warned this is a ‘one-off’ extension and the Commission’s proposal includes a clause which renders it legally impossible for the EU-UK Partnership Council to extend this period further. The rules of origin requirements are therefore locked in from 2027 onwards.” Q BDO www.bdo.co.uk Matthew Clark Reprieve for UK carmakers over EVs and batteries
6 January 2024 Production Engineering Solutions pesmedia.com NEWS Thinking Differently about Finance innovative sustainable connected flexible competitive straight-forward relational simple Call us on01732 833477or visit compassbusinessfinance.co.uk BAE Systems is set for another recordbreaking recruitment drive in 2024, with almost 2,700 new apprentice and graduate opportunities available to young people across the UK. The company has more than doubled its early careers intake in the past five years, offering more young people than ever the prospect of long-term careers supporting the nation’s armed forces and security services. The company’s award-winning early careers schemes are vital to developing the talent pipeline needed to deliver critical national security capability. They also help to build the next generation of talented industrial leaders, with many former apprentices and graduates reaching the top ranks of the company. Charles Woodburn, chief executive, BAE, said: “As the UK’s largest manufacturer, we have sites located right across the country and we’re investing hundreds of millions of pounds to equip young people with the skills they need to achieve their full potential. “Providing high quality apprenticeships and graduate programmes gives young people a route into long-term employment and helps to grow the talent we need to deliver vital national defence and security programmes, including future fighter jets, nuclearpowered submarines and low earth orbit satellites.” More than 1,400 apprentices will join the company, with the majority based in the North of England and opportunities available across the South of England, Scotland and Wales. BAE also plans to recruit almost 1,300 graduates in 2024 – 1,100 more graduate positions compared to five years ago. With more than 60 programmes available, there are opportunities at every level, from steelwork and electrical engineering to cyber security, software development, human resources and project management. Successful applicants have the chance to work on some of the world’s most advanced technology programmes including the Global Combat Air Programme and the UK’s next-generation submarines known as SSN-AUKUS. Megan Pearson, former software degree apprentice at BAE’s air sector, said: “Embarking on an apprenticeship with BAE Systems after I completed my A-Levels helped me become financially independent, which benefitted both me and my parents. I’ve had the chance to work on a range of exciting projects and the flexibility of my apprenticeship means that I’m experiencing lots of new things and not tying myself to any one profession.” The closing date for apprentice applications is 28th February 2024. There are multiple graduate intakes throughout the year, including January, June and September. Q BAE Systems www.baesystems.com/earlycareers 2,700 new BAE apprenticeship and graduate roles Pioneering work conducted by the Manufacturing Technologies Association (MTA) in its quest to encourage manufacturers to decarbonise their production processes has attracted the interest of national broadcaster, ITN. The broadcaster is highlighting the association’s work in a new series named Sustainable Solutions Towards Net Zero. In the programme, James Selka, CEO of the MTA, outlines the association’s goals for a more sustainable future for manufacturing and highlights some of the important work being done by MTA members. The programme also highlights the MTA’s report, Decarbonisation – Future Growth for Manufacturing, which asserts that if the UK was committed to adopting green manufacturing, between £8-£20 billion could be added to UK GDP, as well as creating one million new jobs. The interview was filmed at the Advanced Manufacturing Research Centre (AMRC) and features a specially adapted Caterham sports car kitted out with the latest zero emissions technology. “We have to make UK manufacturing more competitive so that we can increase exports, re-establish the UK as a sovereign manufacturer and reduce our carbon footprint,” said Mr Selka. “The programme underlines how important this work is and coincides with the launch of our Energy Efficiency Knowledge Hub, which will be one of the key attractions at MACH 2024.” The AMRC, one of the High Value Manufacturing Catapult centres, also appears in the programme, outlining the work it is conducting to help manufacturers become more sustainable. This work includes the development of a calculator which looks at converting power monitoring data to show manufacturers where they should concentrate their power consumption to improve their sustainability. The MACH 2024 Knowledge Hubs will focus on educating manufacturers in when and how to adopt new technologies. Each hub will have a dedicated stand within the exhibition zones focused on a particular type of technology: Automation and Robotics; Data and Artificial Intelligence; Energy Efficiency; Additive Manufacturing and Tooling. In recognition of the importance being placed on these hubs, each is being managed by one of the specialist centres from the High Value Manufacturing Catapult. The programme also features Institute of Directors’ chief economist, Kitty Ussher, discussing ways the UK Government can advance sustainability in the business sector. Sustainable Solutions Towards Net Zero is available to view on the ITN Business Hub and the New Scientist platform. To view the programme, visit https:// business.itn.co.uk/programmes/ sustainable-solutions-towards-net-zero/ or www.newscientist.com/sponsored/ ITNBusiness/sustainable-solutionstowards-net-zero Q Manufacturing Technologies Association www.mta.org.uk James Selka DL, CEO of the MTA ITN focuses on MTA’s commitment to sustainability Scan here for more BAE Systems articles Scan here for more Manufacturing Technologies Association articles
Looking for something new and innovative, but also reassuringly familiar, at this year’s Southern Manufacturing Show in February? Then we reckon you, along with hundreds of others, will be making a bee-line straight for our stand (C160). A recently-introduced DN Solutions’DVF 4000 simultaneous 5-axis machining centre making its UK debut at the event, will be sharing centre stage, and the limelight, with a popular and proven 8”chuck Lynx 2100LSYB sub-spindle, Y-axis multi-tasking lathe. It’s a spectacular line-up. A one-hit machining extravaganza. And, not something to be missed. If you’re looking to improve your productivity, process efficiencies and profitability. Or you’re just wondering why so many component manufacturers continue to invest in our DN Solutions’multi-axis and multi-tasking machine tools, year-on-year, we’ll no doubt see you on our stand. All it takes is just one look! To find out more about Mills CNC at this year’s Southern Manufacturing Show - call us on 01926 736736 or visit www.millscnc.co.uk Mills CNC: Like No-one Else! These are the ones you’ve been looking for! See us on our stand C160
pesmedia.com Production Engineering Solutions January 2024 9 NEWS NEWS The UK Battery Industrialisation Centre (UKBIC) has secured a further £38m in funding to upgrade the facility’s scaleup capabilities to support innovation projects for hightech developers and users of battery technologies. The new funding, announced as part of the Autumn statement, is principally for UKBIC’s innovative flexible scale-up line, and builds upon the £36m already committed by the Faraday Battery Challenge in May. Preparatory work on construction of the facility is already underway. The new funding for the national battery manufacturing scale-up facility will enhance its offering to customers and enable activities including: OAdditional electrode production equipment to be installed as part of UKBIC’s new flexible scale-up line OThe installation of a flexible 800m² clean & dry industrialisation space for new manufacturing process demonstrations ODevelopment of advanced digital manufacturing capability to transform how data is analysed for innovative products and processes being scaled up at UKBIC The new capability, which is expected to be operational during 2025, will provide battery developers with an increasingly cost-effective route to market, enabling companies to move from R&D through to large-scale production without having to use overseas facilities. The funding is being provided by UK Research and Innovation, as part of the UK Government’s £610m Faraday Battery Challenge, a national investment programme which is delivered by Innovate UK. The Challenge supports world-class scientific technology development and manufacturing scale-up capability for batteries in the UK. Tony Harper, director of the Faraday Battery Challenge, said: “This new funding will help make UKBIC’s worldclass scale-up facilities an even more attractive proposition to domestic and global battery developers. UKBIC’s flexible scale-up line, in addition to the new dedicated industrialisation space and the introduction of digital manufacturing capability will further help position the UK and UKBIC as the place to go for battery development.” Sean Gilgunn, UKBIC’s managing director, added: “The investment in the new equipment and capability will mean that many more customers will be able to use the facility to seamlessly develop battery manufacturing through to large-scale demonstration. “The added introduction of digital manufacturing at the facility will provide customers with an even better datadriven understanding of their manufacturing processes, a capability which customers will increasingly expect as the industry evolves.” The Coventry-based facility, which opened in July 2021, is used by organisations with new or existing battery technologies and provides battery manufacturing scaleup and skills for the battery sector. Q UK Battery Industrialisation Centre www.ukbic.co.uk £38m upgrade for UK Battery Industrialisation Centre
10 January 2024 Production Engineering Solutions pesmedia.com NEWS UK car production output surged 31.6% in October, according to the latest figures published recently by the Society of Motor Manufacturers and Traders (SMMT). In the eighth month of growth this year, 91,512 units left the factory gates marking the best October performance since 2019. The news follows recent announcements of significant investment into advanced automotive manufacturing, with some £4 billion committed by government and industry combined in November alone, a massive vote of confidence in the sector according to the organisation. Production for both the home and overseas markets grew in October, up 23.9% and 33.4% respectively, although it was exports which drove output. More than eight in 10 (82.3%) cars were shipped abroad, representing 75,343 units, while 16,178 cars stayed in the UK. Export growth was driven by rising shipments to the EU, up 58.5%, which remains the largest market by far accounting for almost two-thirds of exports (65.2%), and Turkey, which grew almost fourfold to make it the third largest market above the US, China and Japan. UK production of battery electric (BEV), plug-in hybrid (PHEV) and hybrid (HEV) vehicles also rose, crucial models that will help deliver Net-Zero, cutting edge jobs and economic growth. Combined output grew 52.1% to represent four in 10 (40.1%) of all cars made in the month, a near record high. Since January, UK factories have turned out 287,408 of these models, up 59.1% on the year before and helping push overall car production up 16.7% to 751,422 units. Mike Hawes, SMMT chief executive, said: “These figures signpost a bright 2024 for the UK automotive sector. Government and industry are committing billions to transform the industry for a decarbonised future. “The Government’s Advanced Manufacturing Plan and Battery Strategy, announcement of permanent full expensing in the Chancellor’s Autumn Statement and the £2bn commitment government has made to advanced automotive manufacturing, underscore the increasing competitiveness of the UK. Automotive remains one of the country’s most critical industries, delivering jobs, productivity and economic growth across the country.” The latest independent light vehicle production outlook has recently been revised up. It anticipates UK vehicle makers will have produced just over one million cars and light vans in 2023, up 18% on 2022, with further growth anticipated in 2024. This outlook was predicated on a workable solution to the EU-UK rules of origin requirements for batteries. Q SMMT www.smmt.co.uk October sees significant rise in UK car production Leicester-based metalwork firm, ADS Laser Cutting, has expressed optimism for the year ahead following a period of strong sustained growth and unprecedented investment in its team and equipment. Known locally as the saviour of the iconic Fox’s Glacier Mint factory, which it purchased three years ago, and now serves as the firm’s 87,000ft2 headquarters, ADS Laser Cutting has a portfolio of global clients that includes Norton Motorcycles, Sandvik and Network Rail. It has recently increased its team of full-time employees by 15% and additionally, three existing managers have been promoted to director roles within the Senior Leadership team. Andy Smith has been promoted from general manager to technical director, Stuart Rowan has assumed the role of production director, and Zeke Keates becomes business support director having started as an apprentice at the firm 10 years ago. Joint managing director and founder, Duncan Keates, commented: “Over the past 18 years since founding ADS Laser, we’ve enjoyed sustained growth. When we started, it was just myself and my brother Stephen with support from our wives Angie and Samantha based in a 3,000ft2 facility. Today we’re the proud owners of an iconic headquarters with an 87,000ft2 facility on seven acres, supported by a highly skilled team and fortunate to work with some of the best clients in the industry. “However, success doesn’t come from sitting still and we recognised the need to invest in our management structure for continued growth and to enable us to meet our ambitious targets. Together, Andy, Stuart and Zeke have demonstrated their passion for delivering the very best to our clients and to supporting our ever-growing team, and I’m delighted to have their support on our continued growth trajectory. We have also recruited three new fabricators and 2024 will see us actively recruit a new cohort of apprentices.” The company has also commissioned a new robotic welding machine worth over £70,000, which will enable the team to deliver further consistency and efficiency in both time and cost for its fabrication services. It has also placed orders worth over £80,000 collectively for a suite of new quality equipment that includes a 2D and 3D laser coordinate measurement scanner, a 3D tripod and associated software. Q ADS Laser Cutting https://adslaser.co.uk L-R: Zeke Keates (business support director), Stuart Rowan (production director), Duncan Keates (MD), and Andy Smith (technical director) Big investments made at Leicester laser cutting firm A growing family-run engineering firm has triumphed at a prestigious national awards event dubbed the ‘Grammys of Entrepreneurship’. Black Hills Products in Northumberland has been awarded ‘Maker and Creator of the Year’ for North East England at The Allica Bank Great British Entrepreneur Awards. The business is run by husband-andwife team David and Lynsey Crossman and provides tailored engineering solutions and fabricated component and assembly services to the UK utilities and renewable energy sectors. Recognised annually as one of the most prestigious accolades in the entrepreneurial world, the Great British Entrepreneur Awards received over 5,000 applications this year, underlining the significance of Black Hills Products’ success. The awards are judged by a panel of some of the UK’s most successful entrepreneurs and business leaders, including the founders of Specsavers, Poundland and Innocent. Highlighting the prestige associated with the event, Dragons Den star and famous entrepreneur Steven Bartlett, called the awards “The Grammys of Entrepreneurship.” Describing why the company was presented with the Maker and Creator of the Year Award, the judges said: “Black Hills Products is a remarkable family business that embodies strong personal values. The judges acknowledged the company’s outstanding success and experience in their field, making it clear that this business truly stands out.” Black Hills Products managing director David Crossman, commented on the win: “It’s a genuine privilege to be recognised for our approach to building the business. We’ve faced some tough challenges from navigating the pandemic to rising operational costs, but we’ve stayed strong, worked hard to nurture our client base both in the region and nationally to create significant growth. “Winning this award is a tribute to the commitment of the whole team at Black Hills; without them none of this would be possible.” Francesca James, founder of The Allica Bank Great British Entrepreneur Awards, added: “I am thrilled to witness the extraordinary achievements of this year’s winners. Their success stories are a testament to the dynamic and innovative spirit that thrives within UK entrepreneurship. “These inspiring entrepreneurs embody the creativity, determination, and passion that are at the heart of our nation’s business success. Their accomplishments not only celebrate their own journeys but also light the way for future generations of innovators and business leaders.” Q Black Hills Products www.blackhillsproducts.co.uk Husband-and-wife team David and Lynsey Crossman, joint directors of Black Hills Products based in Sleekburn, Northumberland Black Hills Products triumphs at entrepreneur awards event
mmc-carbide.com THE FUTURE IS HERE MV INSERTS . UNPRECEDENTED CUTTING SPEEDS . HIGHLY RESISTANT TO THERMAL SHOCKS . OUTSTANDING WEAR RESISTANCE . HUGE RANGE OF APPLICATIONS . CLASS LEADING TOOL LIFE The combination of atoms with different sizes creates an exceptionally hard crystal structure. (Al,Ti)N coating A complete coating technology for TURNING and MILLING grades that sets new standards for tool life.
12 January 2024 Production Engineering Solutions pesmedia.com NEWS EngineeringUK has released a new report which brings together the available evidence on STEM (science, technology, engineering and maths) clubs and their ability to increase students’ aspirations for engineering and technology careers. This rapid evidence review looks at the delivery mode, evaluation, and key findings from engineering and technology-related STEM clubs. Through summarising the existing evidence, the report aims to draw out learnings on STEM clubs that can be used by STEM outreach providers to raise aspirations around engineering and technology careers. Jess Di Simone, senior evaluation manager at EngineeringUK, explained: “Given the limited presence of engineering and technology in school curriculums, high-quality STEM clubs can play a key role in complementing or broadening the STEM curriculum – thereby expanding young peoples’ aspirations for engineering and technology careers. So, it’s really important we understand how to make these initiatives as effective as possible. “We hope the learnings in our report will be helpful for STEM outreach providers and will support efforts to increase the number of young people, from all backgrounds, entering the engineering and technology workforce.” Some of the key learnings highlighted in the report include: O Engage students through practical activities: get students ‘doing engineering and technology’ rather than passively studying from a textbook O Engage experts in the design of club content, such as educational specialists and industry professionals who can ensure that activities are not only educationally enriching, but also closely aligned with current industry practices and trends O Involve role models in club activities: their involvement can expose students to educational or professional STEM pathways O Provide comprehensive training to teachers responsible for delivering club content. Effective facilitators need to have the relevant skills to lead club activities and provide valuable support for students O Consider including competitive elements in clubs to enhance engagement and foster a sense of enthusiasm and motivation among students Q EngineeringUK www.engineeringuk.com Nissan is moving ahead with its plan for a zero emissions future with confirmation that all three models made at its UK plant will go 100% electric. The announcement means the EV36Zero hub in Sunderland, Nissan’s blueprint for future manufacturing, will consist of three electric vehicles (EVs), three gigafactories and up to £3bn investment. Nissan employs 7,000 UK employees and 30,000 jobs are supported in the UK supply chain. Not only does the transformational project include future all-electric versions of Nissan’s flagship Qashqai and Juke crossovers, but Nissan has also confirmed that the third vehicle planned for UK production will be the next-generation Nissan Leaf. Vehicle and battery manufacturing will be powered by the EV36Zero Microgrid, which will incorporate the wind and solar farms at Nissan and will have the capability to deliver 100% renewable electricity to Nissan and its neighbouring suppliers. Announcing the plans at the Sunderland plant, Nissan president and CEO Makoto Uchida said: “Exciting electric vehicles are at the heart of our plans to achieve carbon neutrality. With electric versions of our core European models on the way, we are accelerating towards a new era for Nissan, for industry and for our customers. “The EV36Zero project puts our Sunderland plant, Britain’s biggest ever car factory, at the heart of our future vision. It means our UK team will be designing, engineering and manufacturing the vehicles of the future, driving us towards an all-electric future for Nissan in Europe.” Nissan’s latest investment includes up to £1.12bn into its UK operations and wider supply chain for R&D and manufacturing of the two new models announced, including facility and manufacturing process improvements, skills training, and tooling for suppliers. This follows the £423m investment announced by Nissan in the first phase of EV36Zero for the first future EV. This news builds on Nissan and its partners’ initial £1bn investment to create EV36Zero, transforming its Sunderland manufacturing facility and creating a world-first EV manufacturing ecosystem. The additional two models, alongside an additional gigafactory and further investment for infrastructure projects, will result in an investment of up to £2bn. It means Nissan’s plans for the future electric versions of Qashqai, Juke, and the replacement for Leaf, will enable up to a £3bn investment in the UK. Q Nissan www.nissan.co.uk Walter Tools and Heller have entered a technology and development partnership, the two companies have announced. The collaboration focuses on integrated customer solutions for the machining industry. The companies aim to test, optimise and market their products through the joint development of sustainable machining processes. The two CEOs of the BadenWürttemberg-based companies say they are looking forward to working closely together and are convinced that this is a win-win strategy. Heller CEO, Dr Thorsten Schmidt, commented: “Walter is an excellent technology partner with extensive tooling expertise and a wealth of experience in machining. In addition, Walter provides the necessary tooling technology to give Heller’s customers a direct productivity advantage in metal cutting. Together with the strengths that Heller brings to the table, we are able to forge a strong partnership in the areas of development and technology.” Christoph Geigges, president of Walter, added: “We see many opportunities in working with Heller as they have the knowledge and experience in setting up and machining various workpieces, as required. Together with our large assortment of cutting tools, we can provide the ideal package for customers. To work with Heller on specific application projects, covering components in the automotive and aerospace industries around the world, is an exciting development which will bring benefits for all parties.” The Tübingen-based company has held a strong partnership with Heller for many years, both as a customer and as a supplier. Several Heller machines are already in use at Walter’s technology centres and production facilities. Q Heller www.heller.biz Q Walter Tools www.walter-tools.com Heller CEO Dr Thorsten Schmidt (left) and Walter president Christoph Geigges sign the agreement Walter and Heller sign tech partnership STEM clubs boost aspirations for engineering careers, report shows Scan here for more Walter Tools articles Scan here for more Nissan articles Scan here for more Heller Machine Tools articles Nissan accelerates switch to electric in Sunderland
pesmedia.com Production Engineering Solutions January 2024 13 NEWS MADE IN USA Haas Automation | 01603 760539 | sales@haas.co.uk The world’s best selling VMC for a reason. Auto Parts Loaders | Plug & Play Robots | Integrated Pallet Pools NEW www.haas.co.uk NEWS The winners of the 2023 WorldSkills UK Industrial Robotics competition, held in conjunction with FANUC UK, have been announced at an awards ceremony in Manchester. Representing the best of the UK’s rising robotics talent, Hannah Currie and Peter O’Neill from Northern Regional College in Northern Ireland beat over 50 talented young apprentices and students to take gold at the national finals, held over three days in November at FANUC’s UK headquarters in Coventry. The duo now has the chance to represent Team UK at the WorldSkills International Industrial Robotics competition in 2024. The five teams that made it to the UK national finals were tasked with accurately programming a FANUC ER4-iA robot according to a brief set by the company’s technical team. This involved picking and placing parts and incorporated sensors and pneumatics components, as well as an extension task to create a digital twin. The teams were judged on a variety of skills such as accuracy of programming and equipment installation, as well as teamwork, safety, time management and documentation. The winning team triumphed with an impressive overall score of 97%. Winner Hannah Currie is currently in the second year of a Foundation Degree in Engineering and is pursuing a Higher Level Apprenticeship in Engineering with Wrightbus where she is employed as a manufacturing technician. She said: “It involved a lot of extra work, but it was well worth the effort as the skills we developed and the knowledge we picked up along the way will always stay with us and help us in our careers.” Teammate Peter O’Neill trained as a welder with McAuley Engineering and completed a Foundation Degree in Engineering at Northern Regional College. He is now a second-year BEng Mechanical Engineering student with Ulster University. The finals were judged by a panel of experts from FANUC UK comprising competition organiser and technical manager, Paul Coombes; technical sales support engineer Dan Dunn; Fintan Collins, FANUC UK Academy trainer; and former WorldSkills UK finalist Hara Konstantelia, now a FANUC technical sales support engineer. Ben Blackledge, chief executive, WorldSkills UK said: “This is a lifechanging moment for these young engineers. They are the new generation of highflyers that will give UK employers a competitive edge.” To find out more about the 2024 WorldSkills UK Industrial Robotics competition, including how to enter, go to: https://www.worldskillsuk.org/ competitions/industrial-robotics/ Q FANUC www.fanuc.eu/uk WorldSkills UK Industrial Robotics finalists at FANUC UK with managing director, Tom Bouchier and FANUC Europe CEO, Marco Ghirardello Hannah Currie and Peter O’Neill from Northern Regional College in Northern Ireland took gold at the national finals of the 2023 WorldSkills UK Industrial Robotics competition Student success at WorldSkills and FANUC contest Scan here for more FANUC articles
14 January 2024 Production Engineering Solutions pesmedia.com NEWS Sheffield Forgemasters is positioned to expand into nuclear fabrication after passing a highly testing audit to regain its ASME status as a key supplier of heavy forgings and castings to the civil nuclear power market. The company is on-track to receive its nuclear qualification after an American Society of Mechanical Engineers (ASME) Section III Division I NCA 3300 (NCA 3800), NCA 4000 and NQA-1 Code survey and audit, recommended it for Material Organisation (MO), and welding (NPT) accreditations. ASME NPT (Nuclear Partials) is an advanced accreditation, enabling the historic engineering marque to become the only UK producer of heavy forgings and castings to physically weld-fabricate such safety critical components for the heart of a nuclear power plant. Ian Nicholls, group technical director at Sheffield Forgemasters, said: “Sheffield Forgemasters has passed the ASME audit to qualify as a Materials Organisation with NPT status. The accreditation is a huge development with enhanced requirements and disciplines embracing all our processes, employees and selected sub-suppliers.” Sheffield Forgemasters, which is a crucial supplier to the UK defence industry, will be able to supply ‘material’ (castings and forgings) for civil nuclear applications and carry out weld construction activities on these materials through ASME NPT certification. The ASME CNC committee will need to approve the audit’s findings before the certificate is granted, but once the company secures MO and NPT status it will be one of the only UK companies qualified for main component fabrication within a civil nuclear power plant. Mr Nicholls added: “ASME accreditation opens up significant possibilities for the UK’s own nuclear new-build programme and taps into a growing need for nuclear power to solve the world’s energy crisis. The ASME code is the most comprehensive series of guidelines for civil nuclear manufacture in the world with an emphasis on doctrines that resonate with the European Nuclear manufacturing code, RCC-M and other submarine nuclear standards. “Code compliance is a significant undertaking for any company wishing to enter the UK civil nuclear supply chain, requiring comprehensive understanding to avoid code violation. Businesses will need to understand how to engage with this process and currently, very few UK companies do.” Sheffield Forgemasters first gained ASME accreditation as a Nuclear Materials Organisation in 1992 and will now continue its work to develop manufacturing technologies for the next generation of SMR civil nuclear power plants. Q Sheffield Forgemasters www.sheffieldforgemasters.com Altair, a global leader in computational science and artificial intelligence, has announced, together with JLR and battery manufacturer Danecca, that the companies have been awarded funding from the UK Government through the Faraday Battery Challenge. The three companies have developed a consortium to support a research project to develop a new design process for electric vehicles. The project funding comes from UK Research and Innovation, a non-departmental public body sponsored by the Department for Science, Innovation and Technology (DSIT) to support the development of battery technology in the UK. The new process will leverage Altair technology to develop vehicle prototypes. The new vehicle models will have a new, lighter body that offers more room for the battery without adding additional weight. JLR will also apply Altair’s C123 process, a three-stage concept development process for body-inwhite structures. It will also perform optimisation with Altair OptiStruct – a leading FEA solver in the Altair HyperWorks design and simulation platform – utilising the solution’s newly developed electrothermal features. “We are excited to collaborate with JLR and Danecca on this innovative project to support the next generation of electric vehicles with innovative, efficient designs,” said Royston Jones, senior vice president of automotive, Altair. “Altair’s simulation and data analytics tools will enable the consortium to develop a new design process of electric vehicles and batteries, which will help make these vehicles lighter and more energy efficient.” Paul Haney, battery technology senior manager, JLR added: “This research project with Altair and Danecca marks an important step forward in creating electric vehicles that deliver sustainable e-mobility for the future.” “By partnering with Altair and JLR on this innovative project, Danecca has the chance to advance the development of electric vehicles and battery technology,” said Danson Michael Joseph, managing director, Danecca. “Our expertise in battery manufacturing, combined with Altair’s simulation and optimisation tools, will enable us to create more efficient battery installations that can power the next generation of electric vehicles.” The project runs from February 2023 to January 2025 and will continuously explore how to make improvements through simulation after the components for the prototype vehicles have been ordered. All research results will stay with JLR, Danecca, and Altair after the funded project period and can be used for other customers or projects. Q Altair www.altair.com Sheffield Forgemasters passes civil nuclear accreditation Consortium of Altair, JLR, and Danecca awarded funding Scan here for more Sheffield Forgemasters articles
In Partnership With: SERIES HPM SERIES ‘M’ CONTACT US | OFFICE NUMBER: +44(0)1562 602 333 | EMAIL: Sales@fse.co.uk FSE offer a complete service package from site survey to installation to service and maintenance, giving you peace of mind that you are complying with HSE regulations and protecting your employees from exposure to mist generated by CNC machines. We will provide you with a full-service package to ensure that your employees and your business are protected from the risks associated with exposure to oil mist. FSE offer a range of solution from individual extraction units to central extraction systems to multiple machines, we can also manufacture machine hoods to fully enclosure open machines to make sure your employees are fully protected against exposure to oil mist. Our SWIFT / LEV Indicator is highly visible, with a continuously moving display to indicate either adequate or insufficient airflow. If the fan fails, duct gets damaged, or a blockage reduces the duct airflow, the indicator will clearly show you. 4-stage oil smoke mist filtration. Detailed LED condition & status lights. Flexible installation options to allow easy access for maintenance & system inspection. 1. Next generation colour LED electronic airflow indicator, which instantly shows if the industrial ventilation is controlling airborne contaminants in accordance with HSE258. 2. Displays air temperature on the colour LED screen. 3. Can be powered either by battery or mains power. 4. Built-in battery status condition indicator. 5. Remote to control/calibrate the airflow indicator. EXOMIST ‘M’ SERIES EXOMIST H.P.M. SERIES MACHINE CENTRE HSE Recommended Duct Velocity Option Other Extraction Points May Be Required OR HEPA H13 (EN1822) HSE285 Best Working Practice 99.97% Filter Efficiency s The HSE recommends airflow indicators are fitted to all Industrial Ventilation, or Local Exhaust Ventilation (LEV) systems. Swift Swift+ with additional features including email and/or text alerts On/Off via remote Find Us At Stand J225
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