ADVERTISEMENT Live Machine Demo on Stand 19-330 Complete solutions by HELLER 360° performance for your production Discover solutions beyond the machine from five solution areas, enabling you to produce reliably and competitively – at maximum availability and productivity, 24/7. Heller Machine Tools Ltd. | Acanthus Road | Ravensbank Business Park Redditch Worcestershire | B98 9EX | United Kingdom | uk.heller.biz HELLER UK Manufacturing Facility
In the UK, both 4-axis and 5-axis HMCs are built using flow line manufacturing principles. There are advanced applications engineering capabilities on-site and a well-equipped demonstration area. Customers are welcome to visit to see the quality of engineering input that is standard across all HELLER factories, including in Sorocaba, Brazil (which is also celebrating its 50th anniversary this year), in Troy, Michigan, US and finally in Changzhou, China. Join us at MACH 2024 on stand 19-330 and celebrate with us. It will be an opportunity to see an exciting live machine demonstration on a HELLER HF3500 5-axis machining centre. See you there! HELLER UK Facility Drone Flythrough: The pre-eminent machine tool manufacturer in the machining sector, Gebr. Heller Maschinenfabrik GmbH based in Nürtingen, Germany, is now 130 years old, while its wholly owned subsidiary in Redditch, Heller Machine Tools, is celebrating its 50th anniversary this year. Machines are also manufactured at the UK site, which is a global competence centre for turnkey projects and innovative manufacturing solutions. The symbiotic relationship between the parent and daughter companies, both of which have their own manufacturing programmes serving world markets, results in a level of service to customers that is unsurpassed in the industry, especially in the UK. In 1894, engineer Hermann Heller opened a trading and manufacturing company for patented products and watchmaking tools. He entered the mechanical engineering sector four years later manufacturing sawing, skiving and thread cutting machines, laying the foundations for the long-term success of what is now an international group of companies. HELLER UK CELEBRATES ITS 50th ANNIVERSARY
PES Media Production Engineering Solutions Mid-March 2024 pesmedia.com Transitioning to Net Zero AMRC North West: engineering a cleaner tomorrow Pages 16-18 ukmfgnews Second preview issue pages 23-28
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www.pesmedia.com Production Engineering Solutions Mid-March 2024 3 It’s easy to think of the UK’s objective to reach carbon neutrality by 2050 as something that’s a long way in the future but as we all know, targets of this magnitude simply don’t happen overnight. Without using too many cliches, it is a ‘journey’ albeit quite a long one. And the best approach to achieving success with sizeable undertakings such as this is to take a little and often approach. It requires a plan; it requires accountability; and it requires commitment. Progress will be on an incremental basis. And the wheels of change are definitely moving in the right direction. Leading equipment manufacturers – machine tool producers for example – through their own Net Zero initiatives and pressure from customers and supply chains are taking this very seriously. Generally, machines are being manufactured much more responsibly today, and with intentioned and deliberate consideration for the environment at every stage of the process. From a customer perspective – the people actually buying the equipment – it’s not just solely about feeds, speeds and specifications anymore (although that’s important of course). Nowadays, many end users will want to know how much energy a machine uses, if it has any energy saving technology built-in and the overall carbon footprint. It’s an ever-increasing part of the overall purchasing decision and for the equipment seller, it could ultimately be the difference between making a sale and not. For our cover story this month, I spoke to two guys from the AMRC North West in Lancashire about sustainable manufacturing and factories. The AMRC of course needs no introduction as a world-leading research and innovation network that very successfully bridges the gap between academia and industry. It’s also one of seven centres that make up the High Value Manufacturing (HVM) Catapult. The North West site, located adjacent to BAE Systems’ facility in Samlesbury, is a little different from the others however. It’s the lead site in the group for additive manufacturing; it’s a pioneer in developing battery and battery cell technology; and its home to the largest 5G testbed in the country. But it also operates as a Low Carbon Smart Building Demonstrator. A somewhat ambiguous title perhaps, but it’s pretty self-explanatory. The entire building – including infrastructure, equipment and the manufacturing processes and research carried out within – is designed to be a demonstrator of advanced and sustainable technologies. Check out the article on page 16 for more information, but basically, if you’re a manufacturing company looking for advice on how to start on your Net Zero journey, the AMRC is a great place to start. Dave Tudor Editorial Director Sustainability, green credentials, Net Zero – these are all terms that are interwoven into the very fabric of our everyday lives. And we all know this is about as serious as it gets. In the face of escalating climate change impacts, limiting global warming through carbon emission reduction is paramount to ensure a sustainable future. Dave Tudor caught up with Iain Martin and James Valentine of the University of Sheffield Advanced Manufacturing Research Centre (AMRC) North West to find out more about its sustainability endeavours. See pages 16-18 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 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 27 Issue 335 ISSN 1460-3926 EVENTS April 2024 MACH 2024 NEC, Birmingham, UK 15-19 April 2024 April 2024 CONTROL 2024 Stuttgart, Germany 23-26 April 2024 June 2024 SUBCON NEC, Birmingham, UK 5-6 June 2024 June 2024 TCT 3SIXTY NEC, Birmingham, UK 5-6 June 2024 5 Top trio broadens Dormer Pramet’s nationwide expertise GF appoints new sales manager for Ireland region NEWS MACHINING 14 Hereford manufacturer invests in new VTL from Ward CNC SPECIAL REPORT: SUSTAINABILITY 16 Transitioning to Net Zero TOOLING 19 Ceratizit training days are just what the doctor ordered Fluid power machining solutions EDM 21 No compromise wire EDM MACH 2024 23 Master Abrasives becomes an authorised Rosa machine representative ITC to present new Big Kaiser Innovations at MACH QUALITY & INSPECTION 29 The evolution of manufacturing metrology AUTOMATION & ROBOTICS 32 Learning lessons from Europe The future of automation and AI 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
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pesmedia.com Production Engineering Solutions Mid-March 2024 5 NEWS COMPANY FINDER AMRC 16 Applied Automation UK 9 Bowers Group 11 Bridgeport 6 Ceratizit UK & Ireland 19 Colchester Machine Tool Solutions 6 Control 2024 6 Dormer Pramet 5 FANUC UK 32 FourJaw 10 GF Machining Solutions 5, 21 Group Rhodes 27 Heller 11 Hydrafeed 10 ITC 23 Kyocera SGS Precision Tools Europe 6 Mapal 19 Master Abrasives 23 Numachine 14 PTG Workholding 9 Renishaw 29 Sodi-Tech EDM 27 Starrag 28 TCI Cutting 34 Trumpf 7 TW Ward CNC Machinery 14 Unipart Group 9 Universal Robots 33 Wallwork 9 Yamazaki Mazak 12 EDITORIAL ADVERTISING Advanced Grinding Solutions 28 Akyapak 12 Allied Machine & Engineering 20 Bowers Group 30 Castrol 24 Ceratizit UK & Ireland 36 CNC Robotics 32 Colchester Machine Tool Solutions 8 Grob Machine Tools 10 Haas 11 J&S Engineering 17 Lang-Technik 33 Mitsubishi Materials 13 MTA MACH 2024 22 Muffet Engineering Solutions 15 NJ Metrology 29 Oemeta 5 Rainford 23 Sodi-Tech EDM 26 Swissmatic 14 Sykes Machines 34 tcardsonline 25 Vision Engineering 31 Ward Hi-Tech 7 XYZ Machine Tools 2 Yamazaki Mazak 4 NEWS oemeta.com/uk | 01295 713280 MACH 2024 Stand 20-485 At the start of 2024, Dormer Pramet further strengthened its UK sales team with the appointment of three area sales engineers to cover various parts of the UK. Puru Gunasekaran, area sales engineer for the West Midlands started his career in India working for a technical distributor selling and technically supporting cutting tools, machine tool probes and calibration solutions, working closely with manufacturers. Mr Gunasekaran has an MBA (Master of Business Administration) from Loughborough University and holds a Bachelor of Mechanical Engineering degree. Craig Lampitt, area sales engineer for the East Midlands has excellent knowledge of the territory having spent the past five years building key strategic relationships with some of the largest end users in the area while working collaboratively with key channels. New area sales engineer for the North West, Paul Elliott has been working in the cutting tool industry since 2014 with a particular speciality in the aerospace sector. From his many years in the industry, he has developed solid relationships with key end users and channels in the region. UK sales director Richard Wright commented: “We are delighted to have Puru, Craig and Paul onboard as we make fantastic progress in our growth journey.” Q Dormer Pramet www.dormerpramet.com/uk-ie/en/ GF Machining Solutions, the milling, EDM, laser and additive manufacturing (AM) machine tool specialist and advanced automation and tooling systems supplier, has appointed Gary Purcell as its new country sales manager for Northern and Southern Ireland. Previously employed as an applications engineering manager at Waterford-based Schivo Medical, an innovative contract manufacturing organisation specialising in the medical device and life sciences sectors, and with considerable sales experience from working in and across Ireland’s and Europe’s medical device and mass spectrometry manufacturing supply chains, Mr Purcell joined GF Machining Solutions in February 2024. Employing a sales manager with such extensive, firsthand experience of Ireland’s MedTech sector as well as an in-depth knowledge of medical devices and the manufacturing processes involved in making them, is a significant development for GF Machining Solutions offering significant new business and growth opportunities. Ireland is Europe’s largest per capita employer of medical device professionals and the second largest exporter of medical device products. The country exports MedTech products worth €12.6 billion to more than 100 countries. Ireland is also a global leader in the design, manufacture and supply of cardiovascular devices, orthopaedic implants, diagnostic equipment and surgical instruments – and is home to numerous multinational MedTech companies supported by a large, buoyant and strong supply chain. Mr Purcell commented: “As GF Machining Solutions’ new country sales manager for Northern and Southern Ireland and armed with my knowledge and experience of working in the MedTech sector through my previous employment at Schivo Medical and Takumi Precision in Limerick, I am confident that I can make a telling contribution. “I am no stranger to GF’s advanced machine tool technologies and automation systems, and how they can help, and are helping, Irish component and mould tool manufacturers improve their productivity and process efficiencies. “I aim to use my knowledge and experience to help improve GF Machining Solutions’ sales performance not just in the Irish MedTech supply chain but across the board, with OEMs, tier one companies and precision subcontractors operating in Ireland’s aerospace, pharmaceutical, electronics, materials handling and transport sectors.” Mr Purcell has numerous qualifications (L7 & L8) in sales and marketing, international selling and pharmaceutical and medical device operations. Q GF Machining Solutions www.gfms.com/uk (L-R) Craig Lampitt, Paul Elliott and Puru Gunasekaran Top trio broadens Dormer Pramet’s nationwide expertise Gary Purcell, GF Machining Solutions’ new country sales manager for Northern and Southern Ireland GF appoints new sales manager for Ireland region Scan here for more Dormer Pramet articles Scan here for more GF Machining Solutions articles
6 Mid-March 2024 Production Engineering Solutions pesmedia.com NEWS Bridgeport Machine Tool Company was recently acquired by InCompass, the platform company of Colchester Machine Tool Solutions. As an InCompass brand, Bridgeport will continue to evolve its business with the other InCompass manufacturing partners, contributing to the vision of creating manufactured growth solutions. It means Colchester and Bridgeport effectively become stablemates, pooling their respective knowledge and expertise going forward. The Bridgeport name and legacy live on in the form of various milling machines still in use today, as well as through the influence of its design principles on the machine tool industry. Bridgeport, a leader in metal machining since 1938, offers CNC and manual milling solutions. Renowned for advanced metalcutting capabilities, it caters to a diverse range of industries such as aerospace, agricultural, automotive, construction, consumer products, defence, energy, medical, technology, transportation and more. Bridgeport’s product range supports various applications with precision and reliability, symbolising excellence in the machining world. Its commitment to innovation is evident in its extensive range of CNC vertical machining centres. Bridgeport’s first revolutionary design was the Series 1 standard milling machine which featured a turret-style head that could be swivelled and tilted, allowing for versatile machining operations. The Series 1 quickly gained popularity among machinists and manufacturers due to its simplicity, versatility, and reliability. With the increased awareness of the brand, Bridgeport began to build its legacy and over the years, the company introduced various improvements and innovations to its milling machines, such as digital readouts (DROs), CNC capabilities and other modern features, while maintaining its longstanding reputation in the industry. The latest Series 1 standard knee mill will be present on Colchester Machine Tool Solutions’ stand at the MACH 2024 exhibition taking place at the NEC in April. It will sit alongside Colchester’s range of renowned CNC and manual machine tools, including new Storm vertical milling machines, Tornado CNC turning centres and the Student CNC lathe. Q Bridgeport https://bridgeportmachinetools.com/ Q Colchester Machine Tool Solutions www.colchester.co.uk The next Control international trade fair for quality assurance (QA) held at the Stuttgart Messe exhibition centre will take place from April 23 - 26 this year. The 36th instalment of the show will feature the latest advances from the fields of vision inspection, image processing, sensor technology, as well as metrology. Fabian Krüger, Control project manager at P. E. Schall, promoters of the trade fair said: “We’re once again expecting impressive, trailblazing solutions for quality assurance and an expanded range of topics. QA solutions are used in industrial production, in all operational processes, in non-industrial fields of application, in medical technology as well as in defence applications. “Measurement, testing, inspection, evaluation, documentation and endto-end solutions for these functions is required because more and more data is being captured, analysed, linked and fed back to the respective systems in order to achieve transparency and consistency. This is why software and intelligent evaluation algorithms play an increasingly important role.” Control attracts QA experts from around the world. An intensive exchange of expertise takes place, which is highly valued by exhibitors and expert visitors alike. Solution suppliers come together directly with quality managers, engineers and production experts involved in routine daily operations. As part of Control 2024, the Fraunhofer Vision Business Unit will organise a special show on contactless measuring technology. This show within a show will feature a cross-section of innovative technologies, applications and system components from the field of contactless measuring and test technology across approximately 300m² of exhibition floor space. Currently QA is being driven by automation, digitalisation, networking and inline inspection. Digital mapping of processes, infrastructure and components in real-time is becoming more and more important because these developments serve as the basis for forecasting and optimisation. Digitalised processes make it possible for manufacturing companies to identify quality problems and their causes more quickly. Bettina Schall, managing director of P. E. Schall concluded: “Quality inspection and quality assurance affect all industries and Control 2024 will demonstrate just how rapidly technology is developing. “The show’s user-orientated trade fair format, which features the presentation of top technologies, outstanding expertise, direct practical relevance, and high levels of internationalism, offers ideal conditions for the successful and useful implementation of efficient QA measures in production. Efficient production and remaining competitive are key and in this spirit, we’re looking forward to an exciting and vibrant Control 2024.” Q Control 2024 www.control-messe.de Kyocera SGS Precision Tools Europe has announced the appointment of Paul Burley as its new financial controller. Mr Burley joins the organisation at a pivotal time, collaborating closely with Chris Holehouse who is gradually reducing his hours in alignment with his planned retirement in 2024. This strategic move allows for a seamless transition, ensuring a smooth transfer of knowledge and expertise. Collaborative efforts from Mr Burley and Mr Holehouse during this transition period aim to bring substantial benefits to the team and, most importantly, to valued customers. The company says the well-planned transition will secure the future of its financial operations, as well as enhance the overall experience for its clients. Kyocera SGS is a manufacturer of solid round carbide cutting tools and provides machining solutions and services to a variety of industries, including aerospace, automotive, medical, power generation, mould and die, casting and foundries, general engineering and firearms. The company maintains a customer commitment to providing ‘Value at the Spindle’, whether a client’s value is measured in cost savings, time savings, or ease of use. Q Kyocera SGS Precision Tools Europe www.kyocera-sgstool.com New acquisition means Bridgeport and Colchester become stablemates Control 2024: A marketplace for QA innovation Chris Holehouse (left) and Paul Burley (right) with Hugh Welch, managing director of Kyocera SGS Europe Kyocera SGS Europe appoints new financial controller
pesmedia.com Production Engineering Solutions Mid-March 2024 7 NEWS When you’re considering new equipment make sure you take a look at our extensive, high quality, great value machine tool range. With over 30years experience in supply and service support, Ward Hi-Tech have the machine for you. YES...WE HAVE IT ! Ward Hi-Tech Limited 1 Atlas Way Sheffield S4 7QQ South Yorkshire Tel: 0114 2560333 Fax: 0114 2561629 Email: sales@wardhitech.co.uk www.wardhitech.co.uk when you want it, we have it Hwacheon CNC Lathes and Multi Axis Turning Centres Vertical Lathes, Vertical Machining Centres and Drill Tap Machines Dah Lih Vertical, Horizontal, 5Axis and Double Column Machining Centres Kiheung Bed Type and Travelling Column CNC Universal Milling Machines H.N.K. Heavy Duty CNC Vertical Lathes, Horizontal Boring Machines and Double Column Machining Centres Vision Wide High Speed and Heavy Duty Double Column Machining Centres 5Axis Gantry and Double Column Machining Centres S.F.M. Heavy Duty Flat Bed and Oil Country CNC Lathes *O 4UPDL /08 Trumpf’s Bend TecDay 2024, held at the company’s Luton headquarters in February, proved a resounding success with an impressive number of visitors attending from both existing and potential customers. The highlight of the event for visitors was to get up close with Trumpf’s new TruBend Series 1000 press brake. Designed as the ideal entry to the company’s bending solutions, the new TruBend 1000 offers simple and reliable operation at high levels of precision and speed. The new machine set the theme for Bend TecDay 2024, delivering an easy-tounderstand introduction to the Trumpf world of bending and focusing on all the essentials that provide the ideal start to any company’s bending journey. The TruBend Series 1000 has a sturdy system structure, high-quality components and intuitive programming system, reducing the skill level required for operation. Bend TecDay 2024 included an overview of Trumpf’s TecZone Bend programming software. Visitors could discover how this advanced software automatically creates a program proposal based on 2D and 3D data in just seconds. TecZone Bend is available at no cost for 12 months. Through live demonstrations, attendees could learn about machine attributes such as precision bending: the fouraxis back-gauge positions the sheet metal to within 0.05mm and enables users to bend complex parts with high levels of repeatability and speed (up to 400mm/s). Another key feature is automatic, intelligent wedge crowning, with users benefiting from high angle accuracy along the entire bend length and the automatic calculation of angle correction. Visitors to Bend TecDay 2024 could also see for themselves the machine’s large open height and stroke, its BendGuard optical protection system and the 19” touchscreen user interface fully loaded with Trumpf bending data technology and network connectivity. Notably, the control’s photorealistic 3D visualisation aids both simulation and production, providing operators with step-by-step guidance from tool set-up to component completion. Aside from the TruBend Series 1000, those attending Bend TecDay were able to experience the broad spread of CNC bending machines on show at Trumpf’s Luton showroom. Based on pioneering innovation, the company’s extensive portfolio includes machines for die bending and panel bending, as well as large-format bending tools and fully automated solutions. Q Trumpf www.trumpf.com Trumpf showcases new press brake
+44 (0) 1924 415 000 sales@colchester.co.uk colchester.co.uk Precision. Power. Performance. TRUSTED IN THE INDUSTRY FOR OVER 100 YEARS Find us on 6 - 240 Visit us at stand 15th - 19th April National Exhibition Centre Storm Vertical Machining Centres Tornado CNC Turning Centres Student CNC Lathe Alpha CNC/Manual Combination Lathes CV 400 CNC Turret Mill Series 1 Knee Mill PLUS our all-new Laser Marker to be revealed for the first time at the show! See it all at MACH 2024
pesmedia.com Production Engineering Solutions Mid-March 2024 9 NEWS Mayor of West Midlands Andy Street visited Unipart Manufacturing in Coventry to find out more about green economy job creation. The mayor toured Hyperbat, Unipart’s electric vehicle battery production facility joint venture and a leading UK provider of high-voltage batteries for specialist applications based at the site in Holbrooks. He also visited the Institute of Advanced Manufacturing and Engineering, Unipart’s collaboration with Coventry University to give the next generation of engineers experience in a live factory environment and provide Unipart with cutting-edge research and development. The mayor was hosted by Unipart Manufacturing managing director Carol Burke CBE, who as a West Midlands Regional Business Council member is championing business in the region. Ms Burke is also a non-executive director for the UK Battery Industrialisation Centre and on the UK Battery Strategy Taskforce, which published a report in December on boosting the domestic supply chain for lithium-ion batteries. She commented: “I’m honoured to be working with the West Midlands Regional Business Council. We have a fantastic opportunity to leverage the region’s rich heritage in the automotive industry to embrace alternative forms of propulsion. Through our Hyperbat electric vehicle production facility and the Institute of Advanced Manufacturing and Engineering, our own people and the engineers of tomorrow are building their capability in cutting-edge innovation. “Unipart’s experience is a fantastic example of how businesses in the region can transition to the green economy. As a supply chain solutions and performance improvement technologies partner, and a tier one supplier to original equipment manufacturers, Unipart is supporting our customers’ shift to sustainable technology in the automotive, rail and construction sectors. This competitive edge is at the heart of our manufacturing partner strategy.” Andy Street, Mayor of West Midlands, said: “We have an amazing heritage of car making and innovation in the West Midlands and by working together we can be a world leader in the new clean electric vehicle and battery industries. “Unipart is a wonderful example of what our automotive companies can achieve by embracing change and innovation to put themselves at the cutting edge of the EV industry. They are a key player in the powerful EV cluster around Coventry which includes the likes of JLR and the UK Battery Industrialisation Centre.” Unipart Manufacturing employs 300 people across its Holbrooks site, and its joint venture Kautex Unipart Limited at Coventry Business Park which recently celebrated its 25th anniversary. Q Unipart Group www.unipart.com Leading engineering company Applied Automation (UK) has increased its precision engineering capabilities following the recent acquisition of PTG Workholding. Bristol-based PTG Workholding has been trading for over 30 years and supplies both UK and overseas markets with expanding mandrels capable of automatic and manual clamping in component bores. Thanks to their outstanding accuracy, PTG’s mandrels deliver excellent holding power that can resist even the harshest cutting forces often imposed on the workpiece. Managing director of Applied Automation David Rowe said: “We’ve been looking to increase our existing precision engineering offering and with the purchase of PTG Workholding we will now be able to manufacture custom jigs and fixtures along with specials based around PTG’s standard expanding mandrel range. “It’s a great fit for our business and we’re firmly committed to continue delivering high quality engineered parts at great prices, which was the bedrock of PTG Workholding’s success for more than three decades, to both existing and new customers.” Applied Automation (UK) is an internationally renowned supplier of high-quality automation and control equipment. Based in Plymouth, with satellite offices and warehouses in both Cardiff and Portsmouth, it designs, manufactures and delivers both standard or bespoke automation and control solutions for industrial engineering, the marine sector and smart homes. The company employs more than 150 designers, engineers, project managers, sales engineers and professional specialists who work in a number of specialist divisions and wholly owned subsidiaries, which enables them to provide high levels of technical support and customer service across a number of industry sectors. As a responsible business, Applied Automation recognises the need to build a sustainable world and coupled with its commitment to Corporate Social Responsibly (CSR), endeavours to be a company that can be trusted by all its employees, customers and suppliers. Q Applied Automation UK www.appliedautoamation.co.uk Q PTG Workholding www.ptgworkholding.co.uk Wallwork’s Hot Isostatic Pressing (HIP) Centre has passed EN/AS9100 certification for its new manufacturing process. Installed and commissioned by Quintus Technologies in the last quarter of 2023, the HIP Centre is now entering its fourth month of operation. For customers from a range of industries, the aerospace Quality Management System AS9100 certification provides the highest assurance about the systems in place to ensure Wallwork HIP Centre will meet their requirements. “Preparing for the audit has been a massive effort by all the team,” said Wallwork HIP Centre business manager, David Loughlin. “I extend a personal thank you to all those involved in the process of adding hot isostatic pressing to the extensive scope of Wallwork Bury’s AS9100 approvals. I know they will continue to ensure that the highest quality standards are adhered to on a daily basis.” He added: “With additive manufactured components playing an increasingly vital role in aerospace, demand for hot isostatic pressing is rising rapidly. Adding the second HIP, recently announced, means we will be in front of the curve and ready to provide the high service standards expected by aerospace and all other manufacturers.” The Wallwork HIP Centre is wholly integrated with Wallwork Group’s dedicated national transport systems for speedy pick-up and delivery, assuring aerospace component manufacturers of total end-to-end responsibility for their components. As an entirely UK-based, ITAR compliant business, Wallwork says it is an ideal partner for defence as well as civil aerospace projects. Q Wallwork www.wallworkht.co.uk (L-R) Hyperbat MD Steve Robins, Andy Street, Carol Burke, Institute of Advanced Manufacturing and engineering director Marcos Kauffman and Unipart Manufacturing business development director Andy Davis Unipart Manufacturing hosts Mayor of West Midlands New Wallwork centre secures AS9100 certification Applied Automation acquires workholding specialist Scan here for more Wallwork articles
10 Mid-March 2024 Production Engineering Solutions pesmedia.com NEWS 5-AXIS UNIVERSAL MACHINING CENTERS For the highest accuracy, dynamics & process reliability! IN-HOUSE EXHIBITION April 16th – 19th • Mindelheim, Germany Come and visit us! Get your free ticket now! www.grobgroup.com GROB_Anzeige_5-Achs_UK_180x130mm.indd 1 12.12.2023 13:12:25 Hydrafeed, a leading manufacturer of automation equipment and a subcontract supplier to the aerospace industry, has gained real-time visibility into its factory operations through a new partnership. Machine monitoring technology from FourJaw Manufacturing Analytics has enabled Hydrafeed to meet growing demand with its existing workforce and achieve energy savings worth more than £17,000 a year within a month of implementation. Based in Milton Keynes, Hydrafeed relies on 50 people and 19 milling and turning machines to produce barfeed and machine tool automation products for CNC machine users and several of the world’s most prestigious OEMs. Hydrafeed installed FourJaw’s plug-and-play platform on 14 of its machines in September 2023, enabling it to automatically recognise when they were productive, record reasons for downtime, generate a digital work schedule to guide factory operations and improve communication with machine operators. FourJaw’s platform has provided Hydrafeed with a real-time understanding and visualisation of its factory data, enabling it to establish a production efficiency benchmark and a detailed account of energy use. This has already improved the dayto-day management of manufacturing operations and provided a clear understanding of where Hydrafeed can achieve productivity and sustainability gains. During the first five weeks, Hydrafeed was able to generate the same output in its milling cell with four fewer machines, allowing the reallocation of machine operators to its turning cell, where it has boosted utilisation by 30%. Hydrafeed identified further opportunities to reduce energy usage through more efficient machine operation within days of installation. The energy savings already identified will deliver a complete return on its investment in FourJaw. Paul Gilligan, operations director at Hydrafeed, commented: “We had a strong business before FourJaw but limited visibility of shopfloor operations. We’ve addressed that with FourJaw, and the response from management and machine operators has been positive. Everyone has clarity of what needs achieving and has bought into our plans to improve productivity and profitability. “FourJaw has been a revelation. We’ve already reduced energy consumption and identified further opportunities for improvement.” Chris Iveson, FourJaw CEO, commented: “We see manufacturers who are proactively using FourJaw’s technology, can typically achieve productivity gains of anywhere between 10-20% which can increase output capacity by as much as 30%, so we are excited to see what more Hydrafeed will achieve with FourJaw.” n Hydrafeed www.hydrafeed.co.uk n FourJaw www.fourjaw.com Hydrafeed partners with FourJaw
pesmedia.com Production Engineering Solutions Mid-March 2024 11 NEWS The history of Bowers Group’s Moore & Wright brand is being brought to life by the Hawley Tool Collection as its new exhibition launches at the Kelham Island Museum in Sheffield. With a history dating back over 100 years, Moore & Wright is one of the most prominent names in measurement tools and one that is deeply rooted in the history of the steel city. Famous for its range of tools and measuring equipment, this new exhibition tells the story of the brand and its products, as well as some of its former employees. Bowers Group marketing manager, Ellie Skinner, said: “This new exhibition really demonstrates the impact that Moore & Wright has had throughout its history, and it’s exciting to have our brand being celebrated in its birthplace. Sheffield has such an important legacy in industrial and manufacturing Britain, and it’s a real eye-opener, even to us within the business, of just how much Moore & Wright meant to the people of the city.” The exhibition offers a journey through the brand’s history, showcasing its products and featuring personal stories from former employees. Two years in the making, highlights of the display include a BBC video spotlighting Moore & Wright’s groundbreaking Micro 2000, hailed as the world’s first digital micrometer. Visitors can re-live the experiences of former apprentices while archived photographs capture the company’s vibrant community spirit. For those who have connections to Moore & Wright, the exhibition presents an opportunity to reconnect and maybe even spot familiar faces among the displayed images. Founded in 1906 by engineer Frank Moore and businessman Charles Wright, Moore & Wright quickly became a recognised name in the manufacturing industry, establishing itself as a leading producer of precision 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 Moore & Wright brand shines on Machine tool manufacturer Heller is hosting an open house at its headquarters in Nürtingen, Germany from 23-26 April. Visitors will have the chance to experience the company’s range of machining solutions up close over the four-day event. Highlights will include the latest generation F 5000 5-axis machining centre, a new development concept for a rack-type tool magazine and a machining unit with tilting head kinematics. The open house will feature live demonstrations of 4- and 5-axis machining centres and other Heller solutions focusing on digitisation, automation and services. There will also be factory tours with exclusive insights into production, an exhibition and exchange with partners and companies of the Heller Group. Founded in 1894, the global group develops and produces machine tools and manufacturing systems for machining operations. As one of the leading machine tool manufacturers in the machining sector, Heller employs 2,600 staff worldwide at five production facilities in Europe, Asia and North and South America. The Heller product range includes 4 and 5-axis machining centres, milling-turning machining centres, custom machines and process machines, coating modules, machines for crankshaft and camshaft machining, as well as a comprehensive modular range of services. With Heller4Industry and Heller4Use, the company offers an extended range of solutions to achieve increased productivity and flexibility in production. Heller generates tailor-made complete solutions for a diverse range of manufacturing requirements, from the standalone machine to the fully automated turnkey production system. Customers include companies from the automotive industry and their suppliers, from general mechanical engineering, energy technology, fluid technology, aerospace and other sectors. Q Heller www.heller.biz Heller open house in Germany announced for late April Scan here for more Heller articles
12 Mid-March 2024 Production Engineering Solutions pesmedia.com NEWS measuring instruments and tools. The company’s roots were deeply planted in Sheffield, a city renowned for its industrial heritage. Over the years, Moore & Wright expanded its product range to include a diverse range of high-quality tools and instruments, earning a reputation for accuracy, reliability, and innovation. Today, as part of the Bowers Group, Moore & Wright remains dedicated to upholding its legacy of craftsmanship and precision while embracing new technologies to drive continued growth and success in the global market. The Moore & Wright exhibition is expected to be displayed within the Hawley Gallery, alongside the wider Hawley Collection until the later part of 2024. Q Bowers Group www.bowersgroup.co.uk Scan here for more Bowers Group articles David Martin has joined ScotMaz – the sole distributor of Yamazaki Mazak machine tools in Scotland – as sales manager to support the manufacturer’s growing presence north of the border. Mr Martin, who has 25 years’ experience in the metalworking industry, began his career as a toolmaker before moving into technical sales roles with ABT Machine Tools, Arno UK and most recently Kyocera Unimerco Tooling. He joins ScotMaz with a remit to promote Mazak’s extensive machine tool portfolio to customers in the oil and gas and general subcontracting industries, while also targeting growth opportunities in the country’s aerospace, food and beverage and renewable energy markets. The role will see him work closely with ScotMaz directors Scott and Steven Hunter out of ScotMaz’s Technology Centre in Stirling. Jason Butler, sales director at Yamazaki Mazak, said: “The Scottish market is particularly dynamic and it is not often you find someone of David’s considerable experience in the right place at the right time. “Both our flagship Integrex range of multi-tasking machines and UK made VTC series of vertical machining centres are already popular choices for Scottish machinists with demanding cutting requirements. I am very confident David’s appointment will bolster what is already a robust presence for Mazak in Scotland.” Mr Martin added: “Mazak is one of the iconic brands in the metalcutting industry and, through my tooling experience, I know the company is already the machine tool provider of choice for many Scottish engineering firms. “With more and more customers in need of ancillary support, particularly with offline programming and integrating automation, Mazak’s offering is perfectly placed to deliver a turnkey solution. I’m looking forward to getting out on the road and connecting with many of my existing contacts while forging new relationships throughout the country.” Q Yamazaki Mazak www.mazakeu.co.uk Jason Butler (left) sales director at Yamazaki Mazak, with new ScotMaz sales manager, David Martin Mazak strengthens sales presence in Scotland Scan here for more Yamazaki Mazak articles L-R: Bob Harris (Hawley Tool Collection), Ellie Skinner (Bowers Group), Peter Hawkins (Hawley Tool Collection)
VQSERIES EXTREME PERFORMANCE A typical first gash is combined with an innovative secondary gash to provide high chip evacuation without weakening the structure. NEW DOUBLE GASH GEOMETRY IDEAL for RAMPING 1st Gash 2nd Gash VQ4MVM THE LATEST END MILLING TECHNOLOGY FOR TITANIUM, HEAT RESISTANT ALLOYS, STEELS and STAINLESS. www.mmc-carbide.com
14 Mid-March 2024 Production Engineering Solutions pesmedia.com MACHINING Numachine, a thriving Hereford-based business specialising in CNC machining and subcontract manufacturing, has embraced the advantages of a new Hyundai-Wia LV800RM vertical turning lathe (VTL) supplied by T W Ward CNC Machinery (Ward CNC). The quality and performance of the machine have impressed Numachine in contributing to the optimisation of its manufacturing processes. Brandon Davies, managing director of Numachine and a dedicated mechanical engineer by trade expresses his passion for problem-solving and continuous improvement: “I enjoy solving problems,” he enthuses. “Even if I work 15-16 hours a day, I don’t feel tired because my hobby is my job, and I absolutely thrive on it. I like to come in every day, go around the shop and see how we can improve. I’d say this ethos is something we all share at Numachine; everyone is trying to contribute to our continuous improvement.” Numachine primarily serves industries such as automotive, medical, aerospace, laboratory/ instrumentation, and renewable energy, all requiring the highest quality standards. Mr Davies keeps a keen eye on the electric vehicle (EV) segment, given his personal interest as an EV driver and Numachine’s supply of components to prestigious automotive companies for use in EVs. A key focus for Numachine is cost reduction for customers, achieved through value engineering across the CNC machining process. Mr Davies highlights the company’s diverse capacity. “We have a strong range of CNC machine tools, ranging from various horizontal lathes and mills to 5-axis machining centres, vertical lathes and multitasking machines. This extensive range provides differentiation from the competition, while our inhouse quality control and measurement capability is Hereford manufacturer invests in new VTL from Ward CNC
pesmedia.com Production Engineering Solutions Mid-March 2024 15 MACHINING another key factor for many customers.” He adds “We’re always thinking about how we can expand our service capacities and are now in the process of selecting a metal 3D printer. Additive manufacturing will allow us to produce prototypes much faster for our customers and, with our machining capabilities, we can achieve high-quality finished parts in a very short time period.” Design for Manufacture (DfM) is another significant service at Numachine, actively reducing the cost of machined components for diverse applications, including planes and trains to breweries and roulette wheels. The company manufactures its fixtures inhouse, supporting optimised clamping mechanisms with quick turnaround times, emphasising its role as a onestop-shop, catering to customer demands for high-quality, rapid services. Numachine has recently incorporated a Hyundai-Wia LV800RM VTL from Ward CNC into its diverse machinery lineup. Renowned for its robust and heavy-duty cutting platform, the machine features a one-piece, square-type column that delivers excellent stability. This machine is equipped with a stable shaft structure, providing a high cutting capacity suitable for handling substantial loads. Noteworthy highlights of the Hyundai-Wia LV800RM include a two-step chuck pressure mechanism designed to minimise workpiece deformation and ensure optimal chip evacuation. Within the LV series, a dedicated protection device has been integrated to prevent chips and other foreign materials from entering the main spindle, guaranteeing continued high-precision performance. The Hyundai-Wia LV800RM is characterised by its impressive specification, offering a maximum turning diameter and turning length of 800mm, coupled with a maximum spindle speed of 2,000rpm. This addition to Numachine’s workshop enhances its machining capabilities, reinforcing a commitment to precision and efficiency throughout its manufacturing processes. Speaking on the experience of working with Ward CNC, Mr Davies comments: “It was a very smooth experience. Ward CNC took care of processes such as specifying the machine based on our application, placing the order, delivery, installation, and operator training. “We’re pleased with the quality and performance of the Hyundai-Wia vertical lathe; it’s a good addition to our range of machines. There was only one small issue a few months ago which was solved rapidly by the supplier. We’re completely satisfied with the service. “Looking ahead, Numachine plans to enter the bespoke motorbike and mountain bike manufacturing segment, combining my passion for offroad biking with the company’s manufacturing capabilities. Ward CNC is likely to play a crucial role in these future projects.” TW Ward CNC Machinery www.wardcnc.com Numachine https://numachine.co.uk
16 Mid-March 2024 Production Engineering Solutions pesmedia.com SPECIAL REPORT: SUSTAINABILITY For UK manufacturing companies, transitioning towards Net Zero not only helps address the urgent need to limit global warming but also aligns with national goals to achieve carbon neutrality by 2050. It’s worthwhile setting the scene a little and taking a brief look at the current AMRC structure in the UK. The University of Sheffield Advanced Manufacturing Research Centre is a world-leading and pioneering research and innovation network. It has sites in Rotherham and Sheffield, but also a footprint in Lancashire with AMRC North West, and Broughton, North Wales with AMRC Cymru – a facility it shares with Airbus. The organisation is part of the University of Sheffield – as is its sister centre the Nuclear AMRC and the AMRC Training Centre used to nurture and train the engineers of tomorrow. From a wider perspective, it’s one of seven centres that make up the High Value Manufacturing (HVM) Catapult, a national network of research and innovation centres. To comprehensively list all the work the AMRC is involved with would swell the wordcount of this article unimaginably, but in simplistic terms, essentially it was formed to bridge the gap between academia and industry – turning groundbreaking ideas into reality. It does the research, develops the technology, tests the processes and generally de-risks everything in readiness for manufacturers and businesses to pick up the baton and take things to market. And it’s keen to emphasise that it works with companies at all levels – from primes and mid-tier businesses through to lower tier and SMEs. It’s a misconception that the AMRC exists just for the big boys – it works with the entire supply chain. Often cost-reduction, efficiency and Net Zero pathways are primary drivers. Low carbon transition The AMRC has specialist expertise in many disciplines including digital manufacturing, machine learning and artificial intelligence (AI), composites, automation and robotics, additive manufacturing, testing and training. It also drives forward sustainable manufacturing technologies for Net Zero, creating the vital step changes needed in the low carbon transition. The AMRC North West facility – also known as its Low Carbon Smart Building Demonstrator. Clearly visible in the shot are two state-of-the-art solar flowers which are connected to the building and help reduce its carbon footprint Transitioning to Net Zero Sustainability, green credentials, Net Zero – these are all terms that are interwoven into the very fabric of our everyday lives. And we all know this is about as serious as it gets. In the face of escalating climate change impacts, limiting global warming through carbon emission reduction is paramount to ensure a sustainable future. Dave Tudor caught up with Iain Martin and James Valentine of the University of Sheffield Advanced Manufacturing Research Centre (AMRC) North West to find out more about its sustainability endeavours. PES Report Dave Tudor Iain Martin, senior business engagement manager and senior theme lead for the low carbon smart building demonstrator As a group, the AMRC works very collaboratively and there are many core strategies that are common across all sites but AMRC North West does have some unique skillsets such as our battery and battery cell technology expertise – from design through to manufacturing and assembly
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