Manufacturing & Engineering Production Magazine - October 2024

MANUFACTURING PRODUCTION

TECHNOLOGY & SOFTWARE HOW AI TECHNOLOGIES ARE TRANSFORMING MANUFACTURING

MANUFACTURING

OCTOBER 2024

SHOW PREVIEW

ADVANCED ENGINEERING OCTOBER 30 - 31, 2024

PRODUCTION

ENGINEERING

CONTENTS 38 24

15 Editor

Paul Attwood editor@mpemagazine.co.uk

Senior Editorial Assistant

Anna Startin editorial@mpemagazine.co.uk

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iconsys strengthens sales team with two senior appointments Keynote speakers announced for Advanced Engineering 2024 Digital transformation enables more than cost-savings – it can re-engage the frontline ‘For truly sustainable wind power, we need to extend the lifespan of turbines’ How technology is playing a transformative role in UK manufacturing

Features Editor

Harry Peters editorial@mpemagazine.co.uk

Production/Design

Laura Whitehead laura@lapthornmedia.co.uk

Sales Manager

Charlotte Chapman charlotte@mpemagazine.co.uk

Accounts

Richard Lapthorn accounts@mpemagazine.co.uk

Circulation Manager

Leo Phillips subs@mpemagazine.co.uk

Publishing Director

Maria Lapthorn maria@lapthornmedia.co.uk

Lapthorn Media Ltd

5-7 Ozengell Place, Eurokent Business Park, Ramsgate, Kent, CT12 6PB Tel: 01843 808 102

Editors Note Welcome to the October issue of Manufacturing & Production Engineering Magazine.

In this issue we preview Advanced Engineering 2024 being held at the NEC in Birmingham on October 30th and 31st. With hundreds of suppliers and thousands of engineering professionals in attendance the event provides excellent opportunities for networking and meeting potential new clients.

Paul Attwood Editor

We have a piece by Andie Dovgan, Chief Growth Officer at Creatio, who explains why companies are moving over to no-code platforms and artificial intelligence to avoid the reliance on third party IT providers to oversee digital transformation in the manufacturing industry.

Also in this edition, we have an interesting case study by Robert Schuhmann, Sales Manager of Domestic and Commercial Wastewater for Sulzer pumps. He talks about planning and challenges involved with the disposal of wastewater and rainfall from the new terminal at Frankfurt airport.

We hope you enjoy this issue and as always, if you have any news that you would like to feature, please email details to editorial@mpemagazine.co.uk.

Every effort is made to ensure the accuracy and reliability of material published in Manufacturing & Production Engineering Magazine however, the publishers accept no responsibility for the claims or opinions made by advertisers, manufactures or contributors. No part of this publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including photocopying) or stored in any information retrieval system without the prior consent of the publisher.

mpemagazine.co.uk @mpemaguk

Manufacturing & Production Engineering Magazine

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Company News

New industrial collaboration tackles supply chain challenges Digital Catapult, has today announced that leading technology businesses will join the Made Smarter Innovation Digital Supply Chain Hub programme to apply deep tech solutions to bolster the resilience of national supply chains.

Each company will receive funding of up to £150,000 to address one of three supply chain challenges in cybersecurity, carbon management, and data governance, with a view to strengthening UK industry.

The new initiative will build on the success of the Digital Supply Chain Hub, a programme designed to make UK supply chains more efficient, resilient and sustainable, which has already enabled over forty startups and SMEs to secure more than £3 million in funding. The new participating companies including Orpheus Cyber and Farm Carbon Toolkit and others will accelerate the practical application of deep tech in response to demand from industry, and concerns around future supply chain disruptions such as cyber-attacks, outages and regulatory hurdles.

Orpheus Cyber will look to identify cyber-vulnerabilities and security breaches that could leave supply chains open to cyber-attacks, using data to effectively mitigate risks.

ASG Group Secures Long-Term Agreements with Major Aerospace OEMs, Ensuring Robust Revenue Growth ASG Group, the global aerospace manufacturing conglomerate based in Manchester, has announced the signing of significant Long-Term Agreements (LTAs) with major aerospace OEMs, securing the group’s revenues for the next 5 to 10 years.

These agreements, a testament to ASG Group’s commitment to trust, collaboration, and technological excellence, were achieved through extensive cooperation, transparency,

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and consistent delivery on promises.

The LTAs mark a major milestone for ASG Group and its manufacturing locations under the group capability branded as ‘ASG Aerospace.’ These businesses have been at the forefront of developing and nurturing relationships with industry stakeholders, leading to increased trust and significant longterm commitments.

ASG Group, known for its endto-end manufacturing capability for aerospace flight controls, engine

components, assemblies, and airframe components, serves an impressive client roster, including industry giants such as Airbus, Boeing, Collins, Eaton, Moog, Rolls-Royce and Spirit.

Visitors to the ASG Group stand at this year’s Farnborough International Airshow (FIA 2024) will have the opportunity to company leaders and learn more about the advanced manufacturing capabilities and investment that have driven the company’s success. ASG Group will

Company News Orpheus Cyber will look to identify cybervulnerabilities and security breaches that could leave supply chains open to cyber-attacks, using data to effectively mitigate risks.

By further enhancing its advanced capabilities, and working in collaboration with technical experts from the Digital Supply Chain Hub, Orpheus Cyber will be able to identify vulnerabilities within a supply chain, revealing exposure to data leaks both within an organisations’ own operations and throughout its supply chain network.

The new programme comes as supply chain leaders and businesses across the country face regulatory hurdles, pressure to decarbonise, and cyber-threats to their supply chain. Research has found that almost three quarters (74%) of UK IT decision makers received notifications of an attack or vulnerability in their supply chain software last year, demonstrating the need for increased collaboration between businesses and technology leaders to mitigate this risk.

A showcase event in March 2025 will provide the companies with the opportunity to present their findings to other companies enrolled in the Digital Supply Chain Hub programme, facilitating greater networking and collaboration opportunities to improve the UK’s digital supply chains.

To get involved and connect with supply chain leaders, visit hub.digitalsupplychainhub.uk

showcase its comprehensive quality management system, digital and physical twinning of assets across sites, and the latest investments in automation and machinery.

ASG Group, with operations in eight locations across the UK and Germany, specialises in the production of flight control assemblies, engine components, assemblies, and airframe components.

The company’s unwavering commitment to delivering the highest quality products and services is backed by rigorous quality management systems and continuous investment in cuttingedge technology.

For more information visit https://www.asg-group.co/

AS9100 accreditation helps ACE fly high with £1m of new aerospace opportunities One of Shropshire’s fastestgrowing manufacturers is targeting more opportunities in the aerospace sector after it secured a prestigious quality accreditation.

Advanced Chemical Etching (ACE), which employs 70 people at its state-of-the-art factory in Telford, now holds AS9100 for the first time after it successfully completed its audit in less than five months from the initial gap audit.

Led by Quality Manager Ian Radford, the process involved every member of the company and involved fine tuning its quality management system and introducing problem solving teams to encourage continuous improvement across all the different engineering disciplines.

All share high performance properties and often are manufactured to the tightest of tolerances to achieve significant weight savings.

The scope of ACE’s activities is far and wide outside of aerospace, spanning into Formula One, electronics and the medical industry. This sees the company produce anything from simple washers to highly complex precision components for a wide variety of applications, including battery interconnects, fuel cell bipolar plates, battery grids, cooling plates and heating components.

All parts are developed and manufactured at its main site in Telford and at the company’s dedicated sister business, ACE Forming Limited, in Kingswinford.

This has seen the business consistently achieve more than 97% on time delivery and 99.5% right first time across its customer base of primes and tier 1s.

Sales for this year expect to touch £9m and, with a growing pipeline of interest, the firm is keen to recruit more staff to boost its workforce.

With the quality certification now in place, ACE is planning to increase its work in this sector by an additional £1m of turnover.

For further information, please visit www.ace-uk.net or follow the company on its social media channels.

Advanced Chemical Etching supplies precision components to 25 companies involved in the aerospace industry.

This includes producing parts for the undercarriage, interiors and in engines, with recent ‘wins’ ranging from heat exchangers and actuators to ice protection and components used in galley trolleys.

Manufacturing & Production Engineering Magazine

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Water Processing

Airside water management

Sulzer pumps supporting the expansion of Frankfurt Airport

By Robert Schuhmann, Sales Manager Domestic and Commercial Wastewater

Designing new airport terminals is a complex task and involves many engineering disciplines. While the flow of passengers and luggage are obvious areas for optimization, the planning and design of equipment for managing wastewater and rainwater are equally important, even if they are less noticeable.

Sulzer has applied its expertise to the new terminal under construction in Frankfurt, Germany, to ensure all the wastewater remains out of sight.

Wastewater presents many challenges for the equipment that must collect and transport it to a treatment plant.

These are compounded when the facilities are located in areas of high population density, such as airports, where the additional debris that enters the sewerage system poses a significant threat to the reliable operation of the pumping equipment.

Planning ahead In Frankfurt, a third airport terminal building and apron are under construction and the wastewater system

LEFT: The Sanimat tank was customer designed for this application

The new terminal will have a capacity up to 19 million passengers per year and Sulzer’s expertise has helped to develop an efficient and effective solution for collecting and transporting the water for treatment. In all, 10 pumping stations for rainwater and one for wastewater will be installed, ready for passengers in 2026.

will have to deal with both wastewater and the rainfall, which must be pumped to the local treatment works. Such a large infrastructure project requires considerable planning and Sulzer was brought in from an early stage to support the design and construction of the system to handle this.

Although, the drainage water from the apron shouldn’t cause any issues under normal circumstances, it is kept separate from the wastewater to avoid overloading the downstream station.

If some of the water is contaminated by chemicals, such as jet fuel or fire suppressant foam, it can be diverted to the treatment works, rather than joining any stored rainwater.

Challenging waste The waste that enters the system in airports is surprisingly diverse, including cleaning rags, items of clothing and nappies – all of which pose a significant challenge to any pump. Should a pump become blocked, it needs to be removed from service and cleared. In the meantime, the remaining pumps must cover the pumping demand until the blocked pump is returned to service.

Experience from the pumping stations in Terminals 1 and 2 have highlighted concerns with debris in the wastewater flow that can cause pumps to stop working. Sulzer’s suggestion was to add a Muffin Monster inline grinder, which would ensure continuous pump reliability and an extended service life.

With prevention always better than cure, the installation of a grinder upstream of all the pumps can mitigate the downtime caused by debris in the system. Sulzer’s Muffin Monster has proven its worth in many installations, resolving even the most challenging environments and will LEFT: The Muffin monster inline grinder ensures continuous pump reliability and extended service life.

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Water Processing During the planning phase, care was also taken to use the same pump types wherever possible.

- Robert Schuhmann

provide the same protection at Terminal 3.

Custom tanks The wastewater will be collected in a Sanimat tank that was custom-designed for this application. The inflow will initially pass through the Muffin Monster grinder to ensure that any wipes or other debris

LEFT: The XFP pumps were mounted horizontally on sliding carriages in order to simplify maintenance.

from the terminal will not interfere with the reliable operation of the pumps.

The Sanimat tanks can be specified with tank dimensions to suit the application and ensure that they can be transported through any access or doorways for installation. Applying Sulzer’s design expertise to this project from the outset ensured that the location and capacity of the pumping stations could be optimized for efficiency and reliability.

Rainwater engineering For structural reasons, it was not possible to realize gravity drainage of the rainwater from the piers and the apron.

For this reason, a total of 10 pumping stations of various designs were planned for rainwater and one for wastewater.

The planned and constructed sewerage network on the site of the new Terminal 3 was not designed to absorb the rainwater produced. Through careful planning and prioritization of the pumping stations, the rainwater is disposed of via the sewer network to avoid flooding of the apron.

During the planning phase, care was also taken to use the same pump types wherever possible. This makes it possible to interchange the pumps in the pumping stations in the event of an emergency. This mainly affected the two largest pumping stations, which are responsible for the disposal of approximately 662 l/s. Instead of two large pumps of type XFP501U-SK350, three pumps of type XFP351M-CH350 were planned and installed, making them identical to the pumps in another building.

Manufacturing & Production Engineering Magazine

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Product News

Retrofit Solution Makes Vollmer VGrind 360S Suitable For Processing PcBN The ultra-hard cutting material PcBN achieves the highest degree of hardness and is extremely temperature-resistant, making it a challenge to process. To enable cutting tool manufacturers to grind PcBN cutting edges with the highest level of precision, Biberachbased sharpening specialist VOLLMER has retrofitted its VGrind 360S grinding machine with an optional dressing unit.

The optional dressing unit for the grinding wheel with automatic wheel probing is the key to high-precision grinding of PcBN cutting edges with the VGrind 360S. Working in two work steps for both roughing and finishing, this innovation is a small step for the VGrind 360S, but a giant leap for the world of tool manufacturers.

By adapting its VGrind 360S grinding machine, the Swabian sharpening specialist can make its VGrind 360S suitable for machining PcBN tools (polycrystalline cubic boron nitride). Considered the hardest cutting material in the world after PCD (polycrystalline diamond), the ultrahard cutting material PcBN can achieve an operating life of up to 25 times longer than solid carbide tools. With characteristics such as exceptional chemical resistance even at high temperatures, PcBN retains almost all of its original hardness even at 1200 degrees Celsius. This makes PcBN the perfect material for cutting tools that are used for machining ferrous metals such as grey cast iron and hardened steel.

High-Precision Photocurrent Amplifiers Photonic integrated circuits (PICs) are gaining traction as their potential in creating compact, cost-effective and robust photonic devices is apparent.

As PICs gain popularity in telecom applications, data centres, and various types of sensors, the need for advanced testing equipment becomes critical.

A key part to any new device is characterisation and validation, and for PICs, this requires highly accurate instruments capable of creating and measuring the intricate photonic signals used. Photodiodes are typically integrated within a PIC, and their output when absorbing photons is a small current. This current requires amplification to be accurately measured, without introducing significant levels of noise or additional errors to the measurement. The specific requirements for such a system varies, in certain cases, ultra-fast signals need to be detected reaching up to GHz bandwidths. In others, the noise needs to be extremely low, down to femtoAmpere levels. Regardless of your requirements, LASER COMPONENTS has a solution to offer thanks to its extensive catalogue of transimpedance amplifiers.

This includes the new PCA series highprecision photocurrent amplifier from Quantifi Photonics, which is purpose-built to meet the rigorous testing demands of the industry, providing the confidence to accurately measure the performance of photonic components.

For further information visit: Laser Components - UK

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Manufacturing & Production Engineering Magazine

Door Systems

DOORS READY FOR ACTION

Hart’s Speedors meet requirements Four Speedor high-speed doors have been installed by Hart Door Systems at a major frozen and cooked meat manufacturing in northern England. The doors, at just 1.5m wide and 1.95m high, are the second smallest Speedors ever manufactured by Hart.

“The contract demonstrates two things,” says Gordon Kipling, regional sales manager for Hart. “Not only is our Speedor range available in distinctly different types of doors but where applicable the doors can be available in reduced sizes for precise requirements.

British design and manufacture, wide range of models covering high security, large doors with high wind resistance (3,000 to 5,000 pascals), fire and high speed automation with systems’ interface.

One stop door shop for new installation and/or repairs and maintenance.

“In this case there was a need to protect the production environment against drafts, humidity, dust and dirt by installing our Speedor Cleanroom with its fast opening and closing speed. Our pharmaceutical standard Cleanroom Speedors control airflow thus reducing contaminants.”

Designed specifically for manufacturing and research facilities, Speedor Cleanroom works in strictly controlled environments where hygiene standards are high, such as pharmaceuticals, food processing, electronics and micro-mechanics industries.

The main features of Speedor Cleanroom include maintaining strict air leakage requirements over specified pressure differentials. Complete with an intelligent control panel with digital display each Cleanroom has a reliable and clean in-line drive system complete with an integral safety brake and a non-touch safety light curtain ensures maximum protection to personnel.

Globally recognised Hart’s high speed doors and shutters deliver options and solutions for industry wherever you are.

Take control of your business environment.

Call 0191 214 0404 info@hartdoors.com

Seals minimise pressure drops and protect the manufacturing environment against drafts, humidity, dust and dirt. www.hartdoors.com

Manufacturing & Production Engineering Magazine

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Compressed Air, Pumps & Valves

Elta Sets Sustainability Standards with Engineering Excellence Through New Box Fans As Elta celebrates its 50th anniversary, the company continues to push the boundaries of air movement engineering with the introduction of the latest Qube box fans. Designed with both performance and sustainability in mind, the Qube range represents five decades of engineering expertise, research, and commitment to quality.

The new Qube box fans, available in both EC and AC versions, are a testament to Elta’s adaptability to the evolving demands of commercial and industrial environments. The high temperature Qube has been engineered to meet the stringent requirements of hightemperature applications, making it a perfect solution for commercial kitchens, where temperatures can soar up to 120°C. This focus on extreme operating conditions is crucial in environments where reliable ventilation is not just a convenience but a necessity for safety and efficiency.

a priority, allowing operators to finetune the fans to move and extract air with minimal energy usage. This focus on energy efficiency not only aligns with global sustainability goals, but also helps businesses reduce their operational costs which is a significant consideration in today’s economic climate.

This new design not only optimises space but also enhances the fans’ durability and ease of maintenance.

Qubed and Improved The Qube fans are suitable for extracting air up to 120°C in temperature and come in various box sizes of 500, 670, 820, and 1,020mm. An updated feature of the new Qube range is the inclusion of fully enclosed fan components within the box. This new design not only optimises space but also enhances the fans’ durability and ease of maintenance. The redesigned connections allow seamless integration with ventilation ancillaries such as bolt-on filter boxes, making the Qube fans adaptable to a wide range of installation scenarios.

The double-skinned, noise-reducing box panels are another example of Elta’s attention to detail in engineering. By minimising noise transfer, these fans contribute to a more pleasant working

environment, addressing one of the common challenges in commercial settings. Additionally, the panels are interchangeable, streamlining both the installation process and maintenance tasks, thereby reducing downtime.

David Millward, Product Manager at Elta Group, parent company of Elta, said: “We’ve been listening to feedback from our customers and also looking closely into the hospitality and restaurant market, and can see that there is a gap for high quality, long-lasting, energy efficient ventilation equipment in the commercial kitchen space.

“That’s why we’ve honed the design and features of our already well-received Qube centrifugal box fans. Our newest models are designed to meet the needs of specifiers and contractors working on designing and fitting new commercial kitchens, able to fit into ever-tighter footprints while still being able to offer the high extraction and performance expected from our fans.”

Engineering for Sustainability The EC versions of these fans are designed with energy efficiency as

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As sustainability becomes a growing concern for contractors and businesses alike, the Qube range is perfectly positioned to meet the demands of eco-conscious businesses. This is particularly relevant as restaurants and hotels are increasingly prioritising eco-friendly practices. Esplanade Hotel, in Llandudno, is following the trend and has recently invested £500,000 in a sustainability-focused refurb to prioritise eco-friendly practices. With projects like this becoming increasingly popular, manufacturers must put their emphasis into engineering new products that balance high performance with low energy consumption, to help reduce carbon footprints across the industry.

The Future of Ventilation Elta continues to invest in research and development across its manufacturing sites in the UK and beyond, ensuring that its products not only meet but exceed industry standards. The company’s rebranding earlier this year to unify its operations under one cohesive brand—Elta—further underscores its capability to deliver comprehensive ventilation solutions that extend beyond fan manufacturing.

Looking ahead, Elta remains dedicated to advancing air movement engineering and contributing to a healthier, more sustainable future. With the launch of the new and improved Qube fans, Elta is not just responding to market demands but setting a new standard in ventilation.

For more information about Elta, visit https://eltauk.com/

QUBED & IMPROVED.

BETTER PERFORMANCE, LESS ENERGY. ELTA’S ALL NEW QUBE IS HERE. Standard and high temperature supply & extract box fans built in the UK to the highest quality. Now with Single Phase and EC options, Elta’s Qube range does everything you need it to and more.

With re-engineered movable panels, lower noise levels, and models to withstand high temperatures.

eltauk.com

Scan the QR Code to find out more.

Compressed Air, Pumps & Valves Pneumatic system efficiency Conserving compressed air to reduce energy use can be achieved by employing a number of high and low tech solutions: • Optimise component size • Identify working strokes • Regulate air supply • Air Blowers • Identify and isolate pressure needs

Energy saving solutions A compressed air energy audit will help identify savings as well as ways to improve reliability and extend asset lifespan, says Mark Yates, of compressed air and fluid power specialist Thorite. Here, he explains why.

An air leak detection survey is a valuable way to identify unnecessary waste in compressors. However, to really optimise energy savings, leak detection should form just part of a comprehensive plant-wide energy audit.

presenting an opportunity to reduce process times.

An ISO 11011 certified energy audit will investigate every opportunity to eliminate energy waste and ensure assets are operating at optimum productivity levels. It will also provide a solid foundation for an ongoing maintenance plan.

Recording and analysing your equipment’s air usage identifies patterns and anomalies in the system’s performance, indicating how and where energy savings can be made.

Flow rate sensors A flow rate sensor projects acoustic sounds into the media and measures the sound waves to determine a speed or flow rate. It can also detect the content of the media, for example the gas content in fizzy drinks, pulp content in fruit juice and any solid content in clean-in-place (CIP) systems.

CIP analysis is particularly valuable as it can assess the content to determine when the water is clean,

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Due to EU-wide voltage standardisation in the 1990s, some factories are now being over-supplied with energy from the national grid.

If assets are operating on a higher voltage than required, not only can their reliability be impaired due to increased temperature and vibration levels, but companies are also paying higher energy bills than necessary.

An energy audit will calculate whether assets could operate more effectively on a lower voltage and determine whether installing a voltage optimiser to regulate input could save on both energy bills and maintenance costs.

Reducing energy consumption is a key concern for most companies, with financial as well as environmental motives.

Where energy saving opportunities are identified, bespoke energy efficiency options will be recommended, with detailed analysis of what savings and efficiencies they can offer. In most instances, the solutions will improve reliability and extend asset lifespan.

Voltage optimisation

Smart systems

Data logging systems

Electric automation integration Not all compressors work best on pneumatic systems. If analysis of your compressor indicates that electric automation would improve energy efficiency, this can be integrated into existing machines and systems.

Customised smart systems control panels can be designed and installed, offering specific optimisation to ensure high productivity and efficiency for process-driven enterprises.

Air manager controllers Simple software upgrades allow the master controller in compressors to be expanded without the need for further hardware investment, making air generation more intelligent, dependable and efficient.

Cost benefits The cost of conducting a comprehensive energy audit can be quickly offset by reduced energy consumption and the return on investment is likely to be months rather than years.

Future savings can also be set in place thanks to improved asset reliability and lifespan, reduced downtime and the facilitation of a more proactive maintenance programme.

Add improved sustainability to those benefits and the logic of investing in a comprehensive energy audit is clear.

For further infomation please visit: www.thorite.co.uk

Editor’s Choice

WARDJET and AXYZ to Exhibit at EuroBLECH 2024, 22 - 25 October 2024, Hanover, Germany Visit Stand: Hall 12, Stand A129 for Live Demonstrations and Industry Insights

WARDJET and AXYZ, two industry leaders in cutting and routing technology, are pleased to announce their participation in EuroBLECH 2024, the world’s leading exhibition for the sheet metal working industry.

Attendees are invited to visit Hall 12, Stand A129, to witness live demonstrations, meet industry experts, and explore the latest advancements in waterjet and CNC routing technology.

WARDJET A-Series Waterjet Cutting System At the exhibition, WARDJET will showcase the A-Series waterjet cutting system, known for its unparalleled precision and versatility. Visitors can experience live demonstrations and see first-hand how WARDJET’s A-Series brings the power of large scale industrial waterjet cutting to a complete, yet compact solution. This is an exceptional opportunity to discuss specific manufacturing needs with WARDJET’s experts and discover how our cuttingedge technology can enhance your production processes.

Meet the Experts In addition to live demonstrations, WARDJET invites attendees to connect with

EuroBLECH 2024 Hall 12 Stand A129

Known for their advanced precision routing solutions, AXYZ Routers excel in high-speed cutting and advanced motion control. industry leaders at our stand. Our team of specialists will be available to answer questions and provide insights into how WARDJET’s waterjet solutions can be customised to meet the unique demands of various industries.

AXYZ Routers: Precision CNC Routing Solutions AXYZ, with over 30 years of leadership in CNC technology, will also be featured at the stand. Known for their advanced precision routing solutions, AXYZ Routers excel in high-speed cutting and advanced motion control.

The customisable options, including automatic tool changers, ensure that our machines deliver efficiency and accuracy across a wide range of applications.

Why Visit Us? - Live Demonstrations: See the WARDJET A-Series in action and understand how it can revolutionise your manufacturing process.

- Expert Consultations: Meet with WARDJET and AXYZ experts to discuss your specific needs and explore tailored solutions.

- Cutting-Edge Technology: Discover the latest advancements in waterjet and CNC routing technology designed to enhance precision, speed, and efficiency.

Don’t miss this chance to engage with leaders in waterjet and CNC technology.

Visit us at EuroBLECH 2024 to see how WARDJET and AXYZ can drive your business forward with innovative, reliable, and customizable solutions.

About WARDJET WARDJET is a leading manufacturer of waterjet cutting systems, offering solutions that combine versatility, precision, and cutting-edge innovation.

Our machines are designed to meet the diverse needs of industries ranging from aerospace to automotive.

About AXYZ AXYZ is a global leader in CNC router systems, providing advanced solutions that deliver precision, speed, and efficiency. With over three decades of experience, AXYZ continues to set the standard in CNC routing technology, serving industries such as signage, woodworking, and manufacturing.

For more information see: WARDJET Waterjets: www.wardjet.com AXYZ Routers: www.axyz.com Tel: 01952 291600

Manufacturing & Production Engineering Magazine

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People On The Move

Altus Group Strengthens Support Excellence with New Team Member Altus Group, a leading distributor of capital equipment in the UK and Ireland, is pleased to announce the addition of Michael Bowden to their team as a Service and Applications Engineer. This appointment aligns with Altus’ commitment to continuous improvement and exceptional customer service.

Michael Bowden joins Altus with a wealth of industry experience, having worked extensively in aftersales support for electronics manufacturers since 2006. His previous roles have equipped him with valuable skills and insights that will greatly benefit Altus’ growing installation base. Michael’s track record includes a comprehensive understanding of processes and extensive knowledge on pick-andplace systems, making him an important addition to the team.

Michael will primarily support sites across the North of the UK from his base in Oldham, reflecting Altus’ vision for more localised and dedicated engineering support. His role will involve guiding customers through the entire lifecycle of their projects, from validation and implementation to ongoing usage.

This new hire underlines Altus’ dedication to being ‘Focused on Support Excellence’ and ensuring that the company remains at the forefront of industry developments.

Over the past three years, Altus has expanded its partner network by over 100 sites. In response to this growth, the company is committed to enhancing its support team to maintain the high-quality service its customers expect.

For more information visit: www.altusgroup.co.uk.

McBride appoints Paul Boardman as SAP S/4 Hana Programme Director McBride, the leading European manufacturer and supplier of Private Label and Contract Manufactured cleaning products, has announced Paul Boardman as its new Programme Director for the implementation of the SAP S/4 Hana Enterprise Resource Planning (ERP) system.

Paul will now be responsible for ensuring that programme delivery and business change are working in tandem to achieve the overall programme and objectives. Prior to this, Paul held the position of Group IT Director, and so brings a wealth of experience when it comes to managing digital solutions.

The SAP S/4 Hana system implementation is part of McBride’s ongoing transformation journey. Partnering with digital transformation specialists, SAP, and systems integrators, NTT DATA Business Solutions, the introduction of the new ERP system is the Company’s largest critical project in terms of cost investment and scale.

It will enable McBride to react quicker to its retail and contract manufacturing customer demands, produce at higher volumes and improve internal efficiencies.

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Machines & Machinery Expromet expands in Asia New logistics hub and CNC manufacturing facility to strengthen supply chain solutions.

Expromet Technologies Group is opening a new base within the Philippines Economic Zone Authority (PEZA).The new facility will offer customers extended sourcing solutions, inventory management, faster delivery times and local precision CNC machining capability.

De-risking the supply chain Expromet is a fully integrated, leading-edge supplier of engineered solutions, providing UK-manufactured precision casting and machining solutions alongside extensive supply chain partnerships with worldwide manufacturers.

Global economic, political and social considerations now make it more important than ever to offer an increasingly wide range of sourcing

This will also provide opportunities to eliminate tariffs and benefit from significantly lower costs, giving customers a competitive edge.

Turnkey solutions for demanding sectors PEZA official signing: Maria Veronica F. Magsino (Deputy Director General for Policy and Planning) and Jason Tyas (President of Expromet Asia Inc)

options. Expromet Asia Inc. will initially provide a new logistics and inventory call-off facility, giving worldwide customers: • increased security of supply, minimising risk in the supply chain • reduced lead times through warehousing and inventory management • cost efficiencies and enhanced operational reliability.

On-site CNC machining Expromet plans to provide CNC machining in the Philippines, helping to optimise the efficiency of Expromet’s worldwide manufacturing supply chain.

iconsys strengthens sales team with two senior appointments One of the UK’s fastest-growing industrial automation specialists has strengthened its sales team with an internal promotion and a high-profile appointment to help it achieve ambitious expansion plans. iconsys, which provides control and automation solutions, power conversion and system integration services to more than ten different sectors, has promoted Andy Bunce to Technical Sales Director and recruited Andrew Rushton as Group Sales Director.

This change aims to build on the Telford-based firm’s record year, which has seen it launch two new technical offices in Cheshire and

Expromet supplies precision engineered solutions for performance-critical applications to a wide range of industry sectors, including Aerospace, Automotive and Electronics.

“Expromet Asia will ultimately provide a turnkey solution for customers, including product development, sourcing and inventory management. It is a fantastic opportunity for customers to benefit further from strategic sourcing, optimising cost and lead times without impacting on quality,” says Jason Tyas of Expromet Asia.

To find out more please call Expromet Technologies Group on +44 (0) 1271 866200 or email enquiry@expromet.com

a new automation business and delivering sustained growth through key alliances and developing strategic accounts. iconsys, which has seen its workforce increase by 25% to 81 people, has named Andy Bunce as its new Technical Sales Director.

He has been with the company for 14 years and continues to be instrumental in building its sales and achieving financial success through his relentless delivery of world-class customer service to our clients.

Scotland and increase orders to £14.5m by the end of this year - a £5m boost on the previous twelve months.

Andrew Rushton, a Chartered Engineer, is hugely experienced in developing global sales strategies and delivering sustained growth across several sectors. One of these is energy, which is a key market for iconsys.

Working across the world, Andrew has held several account management and sales director positions for Schneider Electric and ABB, launching

In this vital new role, Andy will take ownership of expanding the technical skills of the growing team and will take responsibility for developing existing and new business opportunities, specifically taking charge of large business pursuits and key bids.

The passionate advocate of using automation to make manufacturing safer and more efficient, he has been with the company since 2010, and his latest role marks the massive impact he has had on winning new business and the successful execution of projects.

For further information, please visit www.iconsys.co.uk.

Manufacturing & Production Engineering Magazine

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Machines & Machinery

Avoid the blind spot

– what does ‘end-to-end’ really mean?

By Arjun Khanna, chief technology officer at labelling and artwork solutions specialist, Kallik.

In the fast-paced world of manufacturing and production, the efficiency of your labelling and artwork management can make or break your business.

Many companies still struggle with fragmented systems, leading to inefficiencies, compliance issues and delays.

An end-to-end solution promises to streamline these processes, but what does that truly entail?

The misuse of buzzwords It’s now over 70 years since Alan Turing posed the question, ‘can machines think?’, in his paper, ‘Computing Machinery and Intelligence’. Since then, we’ve seen the field of science and technology rapidly evolve. Artificial Intelligence (AI), as we know it now, has played a key role in some of the most significant discoveries, helping to diagnose life-threatening health conditions and combat the impact of climate change.

Despite being rooted in our society for over half a century, very few understand the true meaning and capabilities of AI. - Arjun Khanna

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Manufacturing & Production Engineering Magazine

When we look at the manufacturing and production industries, I believe the term is used too frequently. Most often by software vendors not actually delivering a solution that truly is ‘end-to-end’.

- Arjun Khanna

Despite being rooted in our society for over half a century, very few understand the true meaning and capabilities of AI. The same can be said in regard to the term ‘end-to-end’ - an inescapable phrase in both the software and technology industry.

A true definition When we look at the manufacturing and production industries, I believe the term is used too frequently. Most often by software vendors not actually delivering a solution that truly is ‘endto-end’. In my opinion, the definition should be, ‘a solution that offers a seamless workflow, from one feature to the next, all through one single source of truth or platform’.

Over the years, I’ve seen businesses billing their solution as end-to-end, despite integration issues and their customers still having to navigate siloed workflows. This can lead to blind spots and inefficiencies. So what should businesses considering new technology look out for, and how can they be sure that the solution truly is end-to-end?

Firstly, it’s important to establish the difference between integration and

end-to-end integration. Integration refers to the process of connecting one software application with another – the expectation is that your software will share data and information, in real-time, like a fully end-to-end integrated solution, but this isn’t always a guarantee.

The main point of difference here is that an end-to-end solution will allow you to access all relevant information on one single platform, through seamlessly integrated features, in real-time, but without ever having to leave the original application.

The pitfalls of disconnected systems While this is a problem across a number of industries, it’s in my current role, as chief technology officer at Kallik, that I’ve noticed the detrimental impact of disparate, disconnected systems.

In the labelling and artwork space, we’ve spoken to businesses that have fallen foul to the promise of end-toend integration, but instead had to deal with multiple, disjointed systems and remain reliant on outdated spreadsheets.

Machines & Machinery For example, they might have been using label management software to create a label, and its relevant information, but then still requiring a totally separate solution, like Adobe, to fulfil the artwork requirements of the project.

Personnel would have to spend time migrating the asset from one solution to the next, in order to carry out the designs, which could alter both the formatting of the label and risk not being compliant with strict regulatory requirements. Not to mention, being at the mercy of potential human errors and security implications.

There’s also the challenges of version control and traceability - two important factors you would miss out on if the changes were carried out on an unconnected application.

Siloed systems like this can leave a business vulnerable to disruption, and cause a ripple effect right through the supply chain. And, in heavily regulated industries, like the pharmaceutical, healthcare or medical device sectors, this could be disastrous, particularly if the company has thousands of labels to update across a series of products throughout multiple territories.

The solution: Embracing endto-end integration Providing one single source of truth, cloud-based end-to-end platforms like Kallik’s Veraciti enable businesses to react quickly and in real-time to changes across their product lines.

Not only does this offer complete compliance and traceability, to enable businesses to track changes and maintain accurate records across the product lifecycle, users can be confident that they are using accurate, compliant and pre-approved assets.

No more will teams be searching through data silos, or piecing together information from various departments unsure on its accuracy.

Interoperability is key, and one that requires careful planning and robust technology. Firstly, a business should ensure that their solution supports industry standards for seamless communication within existing systems. While there’s no one single platform able to provide end-to-end capabilities, it’s crucial to look out for robust APIs and a suit of pre-built connectors that help to facilitate that all-important integration that will enable seamless, end-to-end workflows where

It’s common that global enterprises will operate a variety of specialised systems tailored to their specific needs.

- Arjun Khanna

data flows smoothly across platforms, reducing both errors and the need for manual data entry.

For example, one single repository of pre-approved assets, through fully integrated ERP and RIM (Regulatory Information Management) systems, can help with version control and allow businesses to maintain their current infrastructure while enhancing their labelling and artwork management capabilities.

It’s common that global enterprises will operate a variety of specialised systems tailored to their specific needs. This makes customisation within a business’ end-to-end software essential, allowing them to adapt to the unique workflows and requirements of the business.

The future of labelling and artwork management The future of labelling and artwork management lies in embracing solutions that not only offer end-toend capabilities but also integrate seamlessly into existing enterprise ecosystems. As technology continues to evolve, so too must the systems we rely on to maintain efficiency and compliance.

By adopting a true end-to-end solution, businesses can ensure they remain compliant, efficient and ready to meet the challenges of the future.

For further information visit: www.kallik.com

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Technology & Software

Why more manufacturers are becoming citizen developers

By Andie Dovgan, Chief Growth Officer at Creatio The manufacturing industry is digitally transforming due to Industry 4.0, pushing manufacturers to adopt new technologies. With 78% of leaders exploring tech solutions to boost efficiency, many are turning to no-code platforms, becoming citizen developers who create their own applications. This shift allows manufacturers to reduce reliance on costly and disruptive external IT teams, keeping control over their digital transformation efforts.

Citizen development and nocode software explained Citizen development empowers non-IT professionals, like manufacturing business analysts, to create custom applications for: customer onboarding, order management, inventory tracking and lead management, without needing to buy off the shelf packaged software or sourcing a third-party IT contractor.

No-code software allows users to create applications without writing code, using visual tools like dragand-drop interfaces. Unlike traditional SaaS packaged applications, which are pre-built and offer limited customisation, no-code platforms enable the design and development of custom solutions tailored to specific business needs. This flexibility allows organisations to quickly adapt to changing requirements and innovate without relying on external IT support.

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Using no-code platforms, manufacturers can easily assemble components to build business solutions that meet their specific needs, similar to building with Lego blocks. This approach simplifies the development process, enabling teams to automate workflows, bring new business applications to life, and reduce costs.

Upgraded with generative AI Historically, these tools were used for simpler tasks such as creating basic forms, managing small databases, or automating routine administrative workflows, and would have still required IT expertise for high-level tasks.

However, recent advancements, including the integration of generative AI (Gen AI), have further enhanced no-code platforms, allowing them to better support mission-critical

business applications, for example sales automation, warranty parts management, product lifecycle management, invoicing and more.

Given Gen AI has grown popular for its ability to create content from simple textual prompts over the past couple of years, it’s proven a useful enhancer for no-code tools. New Gen AI-enabled no-code platforms make application development even faster, simplified, and more intuitive which suits manufacturers’ needs given the industry’s renowned IT skills gap and lack of complex coding background.

With new Gen AI capabilities, professional developers are no longer required to create an entire application from scratch – instead, citizen developers can use prompts to ask a Gen AI-powered no-code platform to create a template of their desired solution, which can be extended with the help of visual no-code designers.

For manufacturers with limited IT knowledge, citizen development offers a practical and powerful way to embrace digital transformation, streamline operations, and maintain a competitive edge in the market.

Manufacturers spearheading digital transformation In an industry where technological advancements are rapidly redefining operations, manufacturers must adapt to remain competitive or risk falling behind. The rise of citizen developers in manufacturing is more than just a trend, it’s a transformative shift that empowers frontline workers to take control of their digital tools.

By enabling non-IT professionals to develop and deploy custom applications, manufacturers can address the IT skills gap in the industry and reduce reliance on costly thirdparty IT resources. This approach not only speeds up innovation but also ensures that those with the most intimate knowledge of the production process can directly influence technological solutions. Through a composable application approach and leveraging no-code capabilities, manufacturers can customise their solutions without a line of code, or any special skills needed!

Process improvement is like cycling.

Everything runs more efficiently with the right partner.

Energy optimization is the key to sustainable production. As a strong partner for strategic energy management, we help you cope with rising energy costs and tighter environmental targets. We are at your side – uncovering the ways to save and be resourceful while maintaining safety, quality, reliability, and uptime.

Do you want to learn more? www.uk.endress.com

Training & Education News adi Group Achieves Silver Standard Status in Make UK Engineering Apprenticeships Employer Kitemark Accreditation Multidisciplinary engineering firm adi Group has been awarded the prestigious silver standard ‘Aspiring for Excellence’ status as part of the Make UK Engineering Apprenticeships Employer Kitemark accreditation.

A leader in the vocational training space, the business offers a range of quality apprenticeships designed to optimise vital hands-on skills development for aspiring engineers.

The business will be celebrating the ten-year anniversary of its award-winning Apprenticeship Academy later this year, spotlighting the incredible successes of the programme to date.

This remarkable new achievement recognises the business’ commitment to investing in the future of the engineering sector as well as continuous improvement and development of its training offering.

The Kitemark is achieved by taking part in Next Gen Makers’ Best Practice Programme, backed by Make UK, which endorses exemplary employers of engineering apprenticeships.

The accreditation positions the business at the same level as global giants such as Siemens, RBSL, Collins Aerospace and many other like-minded firms.

Benchmarking employers’ approach against industry best practice, the accreditation process evaluates businesses’ efforts on criteria including training quality, apprentice support, and overall programme effectiveness. adi Group’s Apprenticeship Academy nurtures young students with a holistic approach, training them in key areas of their chosen engineering discipline with tried and tested methods from highly skilled in-house trainers. adi apprentices are further supported by its Apprentice Mentoring Scheme, designed to ensure every apprentice has the support they need to be successful along their journey, as well as helping them develop skills of importance in the world of work that go beyond engineering knowhow.

Congratulations!

Thousands pick up results in A Level & T Level STEM subjects EngineeringUK statement on exam results Becca Gooch, Head of Research at EngineeringUK, commented: “Congratulations to everyone receiving their A Level and T Level exam results today. STEM A Levels provide a key route into engineering and tech careers, and we are particularly pleased to see a slight uptick in the numbers of girls sitting A levels in computing (17%, up from 15% in 2023) and D&T (32%, up from 30% in 2023) with maths and physics remaining much the same at 37% and 23% respectively.

Our research earlier this year indicated that girls in years 7-9 are switching off from science. It’s therefore important to redouble efforts to consolidate and increase girls’ interest in the key STEM subjects, something we’ll be working on with educators, industry and policy makers.

Today’s results show girls are outperforming boys in computing and D&T in both A*/A and A*-C. In maths, boys did slightly better in A*/A grades and girls better in A*-C. And in further maths, we saw boys do slightly better in A*/A and A*-C grades. In physics, both boys and girls picked up similar A*/A grades with girls slightly outperforming on A*-C grades.

T Levels are growing in the numbers choosing them and the

Manufacturing & Production Engineering Magazine

T Levels are still very new, having only been introduced in 2020 – but more needs to be done to make employers and young people themselves aware of them and their benefits and we need to grow the 9% of females taking engineering and techrelated T Levels.

Between now and 2030, engineering jobs are growing faster than any other occupation – so we really hope today’s results encourage more young people and especially girls - to consider an exciting and rewarding STEM career.

Today may not have gone to plan for everyone, and for young people interested in a STEM career, please remember there are many routes into engineering and technology. Engineering is a broad subject covering a huge number of fields and a number of routes in.

It’s therefore important to redouble efforts to consolidate and increase girls’ interest in the key STEM subjects, something we’ll be working on with educators, industry and policy makers.

- Becca Gooch

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subjects being made available.

Today, 7,380 students will be receiving T Level results, twice as many as last year with 89% receiving a pass. It is fantastic that around half of all T Level students completing their course studied an engineering and tech-related course, but it would be good to see higher grades in Design and Development for Engineering and Manufacturing which at 70% has room for improvement.

A fitness tracker for pallet wrappers.

Percentage Snaps

Film Weight

2.6%

241g

Average Pallets Per Hour

Film Stretch

8

254%

Average No. Rotations

Wrapping Time

23.6

48s

Average Cost Per Pallet

No. Rotations

£0.71

21

Average CO2 Per Pallet

Snapped

0.59kg

No

Total Film Used

Cost Of Pallet

1651.6kg

£0.64

Total Film Cost

CO2 Of Pallet

£4360.24

0.53kg

Total Pallets Wrapped

Time Since Pallet

6166

10h

Kontrol4.0 is an IoT monitoring device which can be retrofitted to any pallet wrapping machine to give you real-time insights into film consumption and machine performance through a simple online dashboard.

Making your job easier by giving you total visibility of your pallet wrapping. lindumpackaging.com

Latest News TS Metals help deliver specialist signs to support Cancer Research UK’s 2024 ‘Race For Life’ promotional activities

When a local, Rugby based, signage company needed some specialist metal work for signs it was producing for Cancer Research UK’s Race for Life, it turned to its long-standing local customer, TS Metals, to stepup to the design and fabrication challenge.

At the start of 2024, specialists in signage, design and branding, ID Genie was awarded a prestigious contract to match a new theme, across all CRUK products, as part of its rebrand. This was needed to help promote its ambitious UK wide awareness and fundraising activities at events including its high profile 3k, 5k, 10k & Pretty Muddy Races, taking place from the beginning of April until late July 2024.

“There was an initial concept to consider but ID Genie were looking to us for guidance and our metal working experience to create the technical designs, prototype for approval by CRUK and then manufacture a practical and long-lasting solution,” explained Ian Addison, TS Metals’ Business Manager. “In addition to aesthetic looks and functionality we also had to ensure longevity and practicality. This meant keeping the weight down to ensure they could be handled, transported and erected by just two people. They also had to remain ridged in use plus stand up to the expected hard knocks they would invariably receive being transported, set-up and then moved to multiple locations.”

Amanda Williams, Owner of ID Genie added: “We have had the pleasure of working alongside CRUK ‘Race for Life’ for many years with their branding, but this year’s rebrand brought us new challenges! One element of the contract was to design and produce a steel structure to stand in front of the existing ‘reflection area’ banners and we turned to locally based TS Metals, for whom we had previously provided site signage, as we knew about their capabilities and expertise when it came to working in metal.

“They effortlessly took the initial concepts through to full technical drawings and a prototype in a matter of weeks, then producing all structures within one month.”

Galvanizers Support Arts & Events Future for Community A West Midlands-based business has supported a renowned local artist in his latest venture – to galvanize the arts and events future for the Wolverhampton community.

Luke Perry joined Matt Lloyd and Giovanni Uche to create and install a series of four sculptures in the Chapel Ash underpass in Wolverhampton, each representing a subject chosen by the local community.

The art pieces were

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Manufacturing & Production Engineering Magazine

commissioned by Roundabout as part of their 12-month project set to bring together Wolverhampton City Council, Art Gallery, and eight community groups, to regenerate the Chapel Ash underpass into an accessible arts and events space.

Edward Howell Galvanizers Ltd is part of Wedge Group Galvanizing Ltd, the largest hot-dip galvanizing organisation in the UK with a history dating back over 150 years. With 14 plants strategically placed across the country, the firm offers a truly national galvanizing service.

For further information, please contact Wedge Group Galvanizing on 01902 601944 or visit www.wedge-galv.co.uk.

Latest News

Alloy Wire International takes the lead with £10,000 Guide Dogs donation

YES YES we get it…

A kind-hearted Black Country manufacturer is helping people with sight loss with its biggest charity donation yet.

Alloy Wire International (AWI), which supplies a range of 60 exotic alloys to over 6000 industrial customers globally, has given sight loss charity Guide Dogs £10,000 towards its wide range of services to support people living with a vision impairment.

Part of its ‘Wired for Good’ campaign, the value of the gift has seen the company name its own ‘guide dog’ puppy ‘Allie’, who is currently going through the training she needs before being placed with an individual.

She will be one of 200 current working guide dog partnerships across the Black Country, Shropshire and Staffordshire.

Paul Chatterley, Sales Executive of Alloy Wire International, commented: “We are very passionate about the communities we operate in and, as part of our commitment to helping people and good causes, we decided to choose Guide Dogs as our latest beneficiary.

“Sight is so important and something that we probably take for granted. The £10,000 donation - our largest yet - will help deliver with and without dog services to people with visual impairments in our region.”

Guide Dogs is the ninth beneficiary of the AWI ‘Wired for Good’ Campaign, which has now directed £50,000 to various good causes across the West Midlands.

With extensive experience in manufacturing and engineering, we’re a little different to most marketing agencies When it comes to what you do, we get it!

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For further information, please visit www. alloywire. com or www. guidedogs. org.uk

Manufacturing & Production Engineering Magazine

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Show Preview: Advanced Engineering

Keynote speakers announced for Advanced Engineering 2024 Two-day event includes talks from over 150 industry experts

Advanced Engineering, the UK’s premier annual event for the engineering and manufacturing sectors, has announced this year’s keynote speakers. The six industry leaders — and 150+ other speakers — will share their expertise and insights on critical industry issues during talks across several different forums. The two-day show will take place at the NEC in Birmingham on October 30 and 31, 2024.

The first of this year’s keynote speakers, Brian Holliday, is a leading figure in industrial technology and digital manufacturing. As the head of Siemens Digital Industries for the UK and Ireland, he oversees advanced automation, industry software, systems integration and R&D. He is an expert on productivity, digital manufacturing and industrial strategy, often contributing to media discussions.

The next speaker Matthew Atkinson, lead research engineer at Jaguar Land Rover, is an expert in automotive engineering, specialising in replacing metallic structures with injection moulded composites. His work focusses on interior mechanical commodities like cockpit, seating and loadspace features and his innovative approach has earned him multiple patents, including for the Range Rover 18MY Executive Seating.

warfare. Shaun has served around the world, from the UK and USA to Afghanistan and Iraq.

Also set to speak are Solange Baena, UK lead for the aviation environmental roadmap at Airbus, and Leonie Moffat, laser radar sales account manager at Nikon. Last but most certainly not least is Stefan Lawrenson, senior polymer chemist at Scott Bader, who specialises in sustainable technology and polymer chemistry. His research focusses on enhancing nanoparticles and synthesising eco-friendly materials.

“This year’s speaker lineup brings together some of the brightest minds in the industry,” said Alison Willis, CEO

of the show’s organiser, Easyfairs UK & Global. “Their diverse expertise will provide deep insights into pressing issues like Industry 4.0, supply chain management and sustainability.

“This lineup highlights the spirit of innovation that Advanced Engineering is all about, and our commitment to fostering knowledge exchange within the engineering community,” concluded Willis. “I’m sure the knowledge and inspiration they’ll bring to the event will be of value to all visitors.”

Advanced Engineering brings together industry leaders and professionals to explore the latest innovations across multiple sectors, including aerospace, automotive, defence and security, marine and more. Attendees can expect presentations on a wide range of topics, from digitally enabled supply chains to advanced propulsion technologies. The full speaker program will be announced soon.

Next, Shaun Harris CBE is currently director of support and chief engineer at the Royal Air Force. With a distinguished 37-year career in the RAF, Shaun has held numerous leadership roles.

His extensive experience spans engineering, logistics and information

For more information and to register online, please visit the Advanced Engineering UK website at www.AdvancedEngineeringUK.com.

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Manufacturing & Production Engineering Magazine

Events & Awards News

Visit LiftEx in London to innovate your lifting safety and efficiency LiftEx 2024, the flagship event of the Lifting Equipment Engineers Association (LEEA), will take place on 16-17th October 2024 at the new West Hall at Olympia in London.

Different Strokes helps Wayne win national Festival of Learning Award Swapping the paint brush for a career in the rail and infrastructure sector has paid dividends for Wayne Hardman.

The Black Country-based trainee trainer’s rapid rise through the ranks at NIS Group was recognised recently at the Festival of Learning in London when he picked up the Learning for Work Award.

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Manufacturing & Production Engineering Magazine

This accolade, which is part of the flagship programme for celebrating lifelong learning, was given to him for the way he chose to change professions to get his life back on track after Covid-19 saw demand for his decorating services fall.

Wayne, who is now on course to become a fully qualified trainer by March 2025, is one of a 50-strong workforce employed by NIS Group.

The company is focused on supporting people into sustainable employment, offering 100 different courses to more than 5000 individuals every year, with 82% of interventions resulting in positive job outcomes in civil engineering, construction, infrastructure and rail.

The award-winning continued with NIS Group securing its own title, winning the ‘Engaging Adults in Learning’ prize at the West Midlands Combined Authority’s Adult Learner Awards.

For further information, please visit www.nisgroup.co.uk or follow the company on its social media channels.

The free-to-attend show is an essential visit for lifting safety professionals and anyone involved in using or procuring lifting equipment or vital supporting services such as inspection, maintenance and training in industries including Manufacturing, Engineering, Construction, Oil & Gas, Offshore, Logistics, Defence, Utilities and Entertainment.

Few venues around the world can match Olympia for location, atmosphere or versatility – it’s a great central location for a truly global industry.

Gather with industry peers, talk to real people and view for yourself the latest lifting products including hoists, mobile and overhead cranes, steel chains, wire rope, winches, shackles, web slings, rigging, spreader beams, height safety and load monitoring equipment, IT solutions and more.

Boost your knowledge Crucially, a visit will contribute to improving safety and best practice with advice from experts on the LEEA stand, while free training sessions and presentations will be delivered at the LEEA Accredited Training Scheme (ATS) seminar sessions, held across both days in the show floor theatre.

Register now for LiftEx 2024 at events.leeaint.com/liftexlondon-2024.

Events & Awards News

Mec Com fabricates a record year to celebrate a quarter of a century in business A precision fabricator and specialist in electromechanical assembly is on course for its best-ever 12 months to mark its 25th anniversary.

Mec Com Fabrications, which employs 230 people across two manufacturing facilities in Hixon and Cluj-Napoca in Romania, is set to hit the £27m sales mark after winning a string of new business in electrical power distribution and the healthcare sectors.

Its order book is nearly 20% up on the budget set in 2023 and is providing a perfect birthday present for the business, a business that was formed in 1999 by a group of employees who reacted to GEC-ALSTOM wanting to outsource its sheet metal and mechanical components manufacturing capabilities – lock, stock and barrel.

Mec Com Fabrications is keen to start laying out the foundations for the next 25 years, with investment planned for its UK headquarters and in European

Fabrications, its hugely successful plant in Romania that is generating €10M of sales in its own right.

The decision to launch an Eastern European operation has been critical to helping the domestic operation withstand offshoring and the two facilities continue to work seamlessly to deliver cost-effective and highquality manufacturing services for its increasingly global client base.

Mec Com Fabrication is planning on celebrating its anniversary with a special party, where staff, former employees and key partners can enjoy a night of entertainment and food and drink at the Staffordshire County Showground in October.

15 Employees, who were there at the very start in 1999, are still working with the business today and will be recognised as part of the celebrations.

For further information, please visit www.mec-com. co.uk or follow the company across its social media channels.

FEG Global celebrates 20 years solving engineering problems across the world Engineering project management firm FEG Global is marking 20 years in business this August. From its conception in 2004 it has grown into a respected international engineering project management operation, with offices in UK and Europe.

Consistent Growth in Sectors, Scope and Markets Based in Washington, North East England, the business provides and engineering project management services to a variety of sectors across the globe, including manufacturing, power, pharma and chemicals and plastics. In particular, its work in the food & beverage production industry is globally recognised, having delivered

projects for companies such as McVitie’s, Hovis and 2 Sisters.

A summer of Celebrations!

The firm is celebrating with a series of events this summer, including a team outdoor pursuits celebration and various “cake parties” – timed with their attendance at exhibitions such as ChemUK and PPMA. The business now boasts some 20+ staff across its engineering divisions and support services, with expertise across mechanical, electrical, chemical, automation and structural disciplines, who work as project managers, engineers or even direct in-house engineering resource for clients. With this scope of team FEG Global has been able to deliver

over £100m+ in work scope over more than 400 projects.

Key Milestones in the FEG Global Journey A family-owned operation, the business is headed by Chris Williams with the support of his wife Grace Williams in the offices, along with the various teams.

The business now plans to build on its success with ongoing international and UK growth, honing in on sectors and industry movements where quality, precision engineering design and project management is valued.

But first, some cake and celebrations.

Manufacturing & Production Engineering Magazine

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Health & Safety

Digital transformation enables more than cost-savings – it can re-engage the frontline

By Sam Byrnes, Chief Product Officer, SafetyCulture Most manufacturers have strictly practical reasons for embarking on digital transformation – they want to increase efficiencies, save costs, and improve productivity. Of course, these are vital for remaining competitive, but there’s another huge benefit to digital transformation which is often overlooked: better frontline morale.

Ironically, many manufacturing and engineering businesses which produce highly sophisticated products are still using paper-based processes that aren’t fit for purpose.

For frontline workers, these clunky outdated processes are demotivating and frustrating, resulting in a host of workforce issues, from high churn rate to low employee engagement.

Even when businesses introduce software, if this isn’t done strategically it can compound the problem. In fact, in a recent SafetyCulture survey, we found that nearly two-thirds (61%) of workers aren’t fully happy with their workplace tools and IT systems. The chances are that your employees find your tools outdated, feel overwhelmed by the sheer number of them, or undertrained to use them.

But businesses that get digital transformation right benefit from workforce transformation too.

One of today’s boldest trends is the move towards paperless, app-based operations. Forwardthinking businesses are investing in easy-to-use, mobile-first workflows which are intuitive – if you can use a smartphone, then you can use your workplace IT. It might seem obvious to give workers kit which is simple to use, but the knock-on impact can be very powerful. Workers feel more empowered in their role, more confident in their skills and development, and more valued by their company – and in our experience, this is actually truer for older generations of workers who built

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Manufacturing & Production Engineering Magazine

their careers around paper-based processes.

Let’s look at an example from the more than 160-year-old Scottish family-owned business Donaldson

Group. With 1,700 employees at 47 locations, the group provides the UK housebuilding industry with a wide range of products and services. But the business conducted 100 monthly internal audits with pen and paper – using around 30 sheets of paper for every three to four sites – a practice which Chief Risk Officer, Mark Murphy, needed to modernise. In 2020, after Mark digitised the company’s audits using SafetyCulture’s platform, he saved 30-40 minutes on each internal audit per employee, not to mention a forest’s worth of paper.

But Donaldson Group was also strategic in its use of internal advocacy. Mark’s approach was to identify the business risk, then find a worker considered a leader by peers, though not necessarily someone in a management role. This workforce leader was trained in the platform and used it to conduct checks. As word of mouth spread and workers saw the benefit of digitisation, more colleagues adopted the platform in their workplace operations. Workers have responded positively to having their feedback heard and gaining a tool that drives efficiency and is tailored to their needs.

Ultimately, frontline morale is a complex phenomenon, and it can be difficult to measure, let alone impact.

But if your workers are frustrated and constantly questioning why certain processes exist, it’s worth listening.

And digital transformation could be the answer.

Sam Byrnes is Chief Product Officer at SafetyCulture, the global workplace operations platform used by 85,000 organisations to complete more than 1 billion checks every year.

Visit safetyculture.com

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People On The Move After five years of driving operational excellence across our operations, I am thrilled to take this next step.

Spring manufacturer, Lesjӧfors, appoints new managing director Luke Smith, formerly Operations Director, has been promoted to Managing Director of Cornwall based Lesjӧfors Heavy Springs UK, succeeding Michael Gibbs.

Michael Gibbs, having taken Lesjӧfors from beach ‘hut’ to two world leading spring manufacturing sites, has

been promoted to European Operations Director for the global Lesjӧfors Group.

Commenting, Luke Smith says: “After five years of driving operational excellence across our operations, I am thrilled to take this next step. It’s an exciting time for our business and with a team that has an embedded

high-performance culture, I’m looking forward to developing our next stages of growth.”

Michael Gibbs concludes: “I could not be prouder of everything the team has achieved over the past 23 years of my leadership. We have grown twenty-fold to become a key supplier to Europe’s automotive aftermarket industry and expanded our manufacturing facilities and capabilities to supply springs across exceptionally diverse industries. We have come a long way since the company’s early days next to Perranporth beach and I am excited to see Luke’s vision take the team to a new level of success. His operational background, customer focused approach, project execution and leadership skills will take the company from strength to strength.”

Unipart Group Announces the Appointment of Dr Bryan Jackson CBE as Non-Executive Chair Unipart is pleased to announce the appointment of Dr Bryan Jackson CBE to the role of Non-Executive Chair from 1st September 2024. This follows the announcement on 14th August 2024 that Unipart’s Founder and Executive Chairman, Dr John M. Neill CBE, will retire from his position effective 31st August and will continue to support the business until the end of November.

Bryan built an extensive career in automotive and manufacturing, beginning his career with the Ford Motor Company where he spent 23 years before joining Toyota Motor Manufacturing (UK) Limited in 1990. He has worked across many disciplines, holding senior positions and managing several plants in the UK and Europe covering the full range of vehicle manufacturing. He retired as Managing Director in 2004 and was an advisor to Toyota in Europe until 2009.

Bryan has a long association with Unipart, commencing in 2005 with his appointment as Deputy Chairman of the Unipart Manufacturing Group. He joined the Board as an independent NonExecutive Director in April 2013 and was appointed Senior Independent Director in November 2022.

Bryan has significant Board-level experience gained across a variety of industries. Previous Board roles include being Chairman of Sharing in Growth UK Limited, Wesleyan Assurance Society, the Royal Orthopaedic Hospital NHS Foundation Trust, the East Midlands Development Agency (a government appointment) and the

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Manufacturing & Production Engineering Magazine

East Midlands Regional Council of the Confederation of British Industry. He is currently Non-Executive Chairman of John Smedley Limited.

He was awarded an honorary doctorate in business administration from Nottingham Trent University in recognition of his contribution as an industrialist and champion of economic growth.

Bryan is a Fellow of the Manufacturing Technology Centre. He also attended executive development programmes at INSEAD Business School, Fontainebleau and Wharton Business School, University of Pennsylvania.

In 2000, Bryan was awarded an OBE for services to the motor manufacturing industry and in 2012, he was awarded a CBE for services to economic development and manufacturing.

People On The Move Alwayse Engineering appoints new Head of Global Partnerships Dean Falconer has joined Alwayse Engineering as the company’s new Head of Global Partnerships.

Having started his career as an apprentice with RollsRoyce before qualifying as a mechanical engineer, Dean also brings with him 17 years of experience in sales at companies including Gould Alloys (part of AMA Metals Group), Trelleborg Sealing Solutions and Integrated Polymer Solutions.

Alwayse is the leading designer and manufacturer of ball transfer units and currently exports to over 70 countries. As Head of Global Partnerships, Dean will be tasked with growing the company’s extensive network of partners and distributors around the world.

He joins the company at an exciting time and is the latest in a series of senior hires that includes Claire Umney as Managing Director and James Turner as Head of Sales for UK & Ireland, following the acquisition of the Birmingham-based engineering company by Lifco AB in 2023.

Dean comments: “After my first week at Alwayse I can see so much potential already. We have fantastic products, a growth mentality and a great team culture.

Everyone is pulling in the same direction to achieve a common goal. For me, the mission is to grow the sales with our Global Partners by finding new applications and revenue streams to explore as well as growing market share in existing markets.”

Claire Umney, Managing Director of Alwayse Engineering, adds: “Dean has the ideal combination of first-hand engineering allied to technical sales experience that enables him to really understand the high loadbearing challenges many of our potential customers are facing. We have some very ambitious plans to grow our international customer base and Dean’s appointment is a key component of our business development strategy.”

For further information: www.alwayse.co.uk.

EEMUA Training for Mechanical Integrity with reality built in…

Developed and verified ‘for industry, by industry’, EEMUA 231 Mechanical Integrity courses with reality built in for industrial engineers at every career stage.

For efficient hands-on work with primary containment – to prevent loss of hazardous substances.

. . . . . .

Satisfy industry requirements at each competency level – Awareness, Basic application, Practitioner.

Certificated courses – by robust examination, valid up to 5-years.

CPD-approved courses.

Flexible delivery to suit learners and companies – Blended, Live online, Classroom, E-learning, In-house.

Available to all – free or discounted to EEMUA Members.

Select from courses throughout each year, including:

Mechanical Integrity Practitioner Certificate (MIPC®) – blended, live online learning for on-site application of EEMUA 177, 231 and 232 guidance, and the PSSR ACOP – certificated for 5 years via a proctored exam and portfolio assessment – Continuing Professional Development approval – Learning on the Next course begins 21 October 2024 for 27 weeks, at 4 hours per week. The MIPC course adapts to engineering needs of each Learner, company and site by a 2-hour induction to fit work from 23 September 2024.

EEMUA 231 Mechanical Integrity Basics – certificated via exam – blended, online learning – Basic application competency level – 4 hours of learning per week for 3 weeks – Next course starts 30 September 2024..

EEMUA 231 Mechanical Integrity e-learning – at the Awareness level– immediatelyavailable on-demand – with Continuing Professional Development approval..

EEMUA 231 Mechanical Integrity In-house training – running over 1 day or 2 half-days – set at the Awareness level – by arrangement, for your choice of time, location, and method of learning – certificated, Continuing Professional Development approval. online-learning@eemua.org +44 (0) 20 7488 0801 www.eemua.org

Manufacturing & Production Engineering Magazine

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Automation M-Files provides process and workflow automation to the consumer goods manufacturing industry, enhancing efficiency and transparency M-Files helps leading companies in the consumer goods manufacturing industry transform how documents are managed and processes are automated.

The M-Files knowledge work automation platform has enabled businesses to increase efficiency and transparency in their day-to-day operations by leveraging innovative document management technologies and streamlining workflows. This has significantly reduced manual errors, strengthened security and compliance, and enhanced collaboration between teams.

The challenges M-Files was responsible for implementing a diverse range of technical and business-focused solutions across a range of consumer manufacturing clients, aimed at improving information management and organisation. These solutions ensured that data and information were easily accessible, wellorganised, and effectively managed.

By doing so, they streamlined business operations and heightened productivity.

One of the biggest challenges was tracking employee data, especially for absences due to illness or vacation.

Manual process control and individual paper or document filing systems were typically used as record keeping tools.

Organisations in the consumer goods manufacturing industry often face the difficult task of streamlining their processes and establishing consistent procedures across multiple countries. This challenge is due to several factors, such as varying laws and regulations, cultural differences, language barriers, and differences in technological advancement.

Manufacturing & Production Engineering Magazine

3. Unified systems Efficient workflows have solved the problems of lost paper-based and electronic documents and the physical handoffs of documents across departments that wasted time.

As a result, paper costs have been reduced, and project transparency has increased.

4. Digital Workflows As customs documents were previously processed and archived manually, digitising the process was determined to be the best solution to reduce employee workloads. This resulted in the digitisation of customs documents being the first use case of M-Files.

The results

As a result, organisations often need more consistency and efficiency in their operations to improve their overall performance and profitability. There is a risk of the rapid accumulation of data where documents become more disparate, while manual processing of incoming documents could also be made more efficient.

The solutions M-Files enabled organisations to automate manual processes, improve compliance, reduce risk, and improve the quality of customer service. It also provided a secure platform for organisations to store, access and share data. M-Files was a comprehensive solution to help consumer manufacturing companies improve efficiency and customer satisfaction. The organisation has a specific focus on the following four areas: 1. Modern contract management M-Files implemented a new contract management system that processes contracts according to uniform rules, archives them securely, and ensures compliance with the law.

2. Digitisation of customer files M-Files streamlined customer communication by gathering all the pertinent documents involved in key processes, such as orders, delivery bills, invoices, and correspondence. This guarantees that all communication related to a customer is managed in one centralised location, providing complete transparency regarding

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ongoing activities, open processes, and customer history.

M-Files implemented standardised procedures globally to optimise processes for consumer goods manufacturing industry organisations.

The solution ensures transparency, compliance with legal data processing and archiving requirements, and efficient procedures.

Consumer manufacturing industries need to stay competitive, and M-Files is the solution they need to achieve that. With M-Files, these industries can streamline their processes, reduce manual errors, and increase efficiency, directly leading to cost reduction and longer-term profitability.

This, in turn, leads to cost reduction by minimising wasted resources, optimising production schedules, and improving overall productivity. When consumer goods manufacturing industries increase efficiency through M-Files, they reduce costs and improve overall productivity.

This is particularly beneficial for consumer manufacturing industries, as they can use the extra profits to invest in research and development, upgrade their equipment, and remain competitive. By doing so, they can achieve long-term success and maintain their position as industry leaders.

With increased profitability, these industries can attract more investors and secure funding for future growth and expansion initiatives. Ultimately, it creates a sustainable business model that ensures the longevity and success of consumer goods manufacturing companies.

Editor’s Choice Why being direct is best for manufacturing and engineering

Going direct Most businesses can describe their ideal customer! Perhaps there’s a local company who’s evaded their charms – or another for whom they could do a better job than their competitor.

Marketing can be criticised for being too general. But it doesn’t have to be. Being targeted often delivers the greatest results for manufacturers and engineers.

In its purest form, direct marketing means making an approach by email, letter or in person. However, it can also include hanging out in the same places as customers - such as trade events, social media or the press and websites they read.

Sarah West of Full Mix Marketing takes a look at direct and indirect marketing and which is best:

Which works best?

The indirect approach For most, the ideal outcome from marketing is to attract customers actively looking for what you do (often called ‘pull’ marketing).

It’s the basis of most digital marketing, including search engine optimisation (SEO), paid search (PPC) and online advertising.

Most businesses get the greatest results from a mix of direct and indirect marketing. However, when resources are limited, the direct approach may offer the greatest potential.

Social media can be used to connect with important individuals and your expertise can be highlighted in content marketing sent to press and websites keen to share articles.

Our top tips are: 1. Be specific but make sure your target list is large enough to deliver results 2. Be persistent and consistent. It can take several exposures to your direct marketing before customers respond As East Anglia’s leading B2B marketing agency, we deliver effective marketing for companies across the UK in manufacturing, engineering and technology.

For more help, visit fullmixmarketing.co.uk

What’s the secret to success?

A database of businesses can often be easily sourced, within GDPR rules.

Email and fulfilment services make it simple to send carefully designed messages.

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Case study

Case Study: Mint Ltd’s Strategic Implementation of AXYZ Routers for Enhanced Retail Display Production Mint Ltd, established in 2010, has carved a niche and rapidly established itself as the pre-eminent provider of innovative retail displays, windows and pop-up spaces.

Serving high-profile clients in the luxury retail, skincare, and beauty sectors, Mint focuses on creating impactful bespoke solutions and brand experiences while emphasising sustainability and local production by leveraging local supply chains.

With 12 years of dedicated service to the retail industry, Mint designs and manufactures up to 90% of its products in-house in the UK, adhering to ecofriendly practices. Their dedication to quality and innovation has positioned them as a leader in creating impactful retail environments. “We are constantly evolving along with our clients’ needs and striving to exceed expectations to ensure that we design, produce and deliver each project to the highest possible standard and quality. All

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Manufacturing & Production Engineering Magazine

designs are made with the planet in mind. We pride ourselves on offering a UK-based sustainable supply” said Stephen Hughes Managing Director.

Challenge: As Mint Ltd expanded its client base and project scope, the need for increased production efficiency and quality became evident to meet the increasing demand for customised retail installations, the company faced significant challenges and Mint required technology that could overcome these:

• Need for Precision: high-end

retail clients require precise and high-quality craftsmanship in their displays, necessitating exact cutting of materials like plastics and polystyrene.

• Scalability Issues: the growing

number of projects and complexity of designs called for enhanced

production capabilities that could not be met with manual processes alone.

• Sustainability Commitments: Mint

aimed to maintain its sustainability standards while scaling up production, which required advanced technology that could minimise waste and optimise material usage.

Solution and Implementation: Mint Ltd chose to integrate AXYZ routers into their manufacturing process, having exclusively used AXYZ’s technology from the outset with the Pacer series of machines. The decision was driven by the routers’ reliability, the strong support from AXYZ and the advanced features such as camera registration that significantly enhance precision and efficiency. Mint Ltd’s long-standing partnership with AXYZ provided a clear pathway to addressing these challenges through the adoption of advanced CNC routers. “We have only ever used AXYZ

Case study machines; we would not use another supplier. We are familiar with the technology and have a great relationship with AXYZ. Reliability is first class”, said Stephen Hughes.

The decision to use AXYZ’s technology was based on several factors:

Implementation and Results: The AXYZ routers have been instrumental in automating the cutting of plastic and polystyrene materials, a critical part of Mint’s production. This automation has led to several key improvements: 1. Increased Productivity and Efficiency: the camera registration technology has minimised errors and reduced setup times, streamlining the production process, allowing for quicker transitions between different production runs and allowing Mint to handle larger volumes and more complex projects with faster turnaround times.

2. Cost Savings and Increased Profitability: With shorter setup times and reduced material spoilage, Mint has observed significant cost savings. These efficiencies have translated into increased profitability, enabling them to invest in further growth and innovation, thereby lowering costs and supporting Mint’s sustainability objectives.

3. Enhanced Product Quality: The precision of the AXYZ routers ensures that each piece is cut with exacting standards, leading to higher-quality final products that meet the demands of Mint’s high-end clientele. The advanced routing capabilities enabled more intricate and personalised designs, providing Mint with a competitive edge in bespoke retail solutions.

We are constantly evolving along with our clients’ needs and striving to exceed expectations to ensure that we design, produce and deliver each project to the highest possible standard and quality.

- Stephen Hughes

4. Positive Impact on Workforce: The introduction of AXYZ routers has been well-received by Mint’s employees.

Automation has not only eased the physical demands of production but also allowed staff to focus on more skilled aspects of the manufacturing process. Employees were trained to operate the new technology, which not only increased job satisfaction through skill enhancement but also added value to Mint’s workforce.

5. Maintenance and Support: Mint’s proactive approach in setting up comprehensive service agreements with AXYZ ensured that the machines were regularly serviced and maintained, avoiding potential disruptions in their production cycle.

The INFINITE The most recent acquisition was the purchase of three INFINITE routers, two of them were the 4008 size Infinite with

7G Auto tool change and the other was slightly larger 4010 size. The INFINTIE is a highly configurable CNC machine that is suitable for one-off, small batch production as well as high volume and high productivity applications, including woodworking, plastic fabrication, engineering plastic machining and so much more. For a wide range of routing operations, one can choose from highspeed spindles ranging from 5HP to 15HP. For knife cutting, choose from a tangential knife, which can be used for creasing and folding applications or an oscillating knife which can be used to process soft goods material.

Future Outlook: While the current focus remains on optimising the use of existing machinery, Mint faces challenges related to rapid expansion, such as space constraints and the need for more machines and staff. The future might include further integration of automation technologies as part of their scaling strategy, although specific plans are still under development. Strategic planning is ongoing, with a focus on maintaining agility in operations and excellence in production.

Conclusion: Mint Ltd’s implementation of AXYZ routers demonstrates a successful alignment of technology with business objectives, leading to a transformation in its production capabilities with improved efficiency, cost savings and product quality. This has enabled the company to scale operations while adhering to its high standards of quality and sustainability. As Mint continues to grow and adapt to market demands, the strategic use of technology will undoubtedly play a crucial role in maintaining their market leadership and commitment to sustainability. This case study exemplifies how targeted technological integration can resolve specific business challenges, leading to improved efficiency, reduced costs, and enhanced product quality - all of which are critical for maintaining competitiveness in the dynamic retail display market.

Contact information: For more information on the AXYZ range of routers contact us today or visit our website.

Tel: 01952 291600 Email: enquiries@axyz.com Web: www.axyz.com

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Latest Product Launches

Walter extends milling cutters with Xtra·tec® XT M5250 Walter has extended its range of Xtra·tec® XT milling cutters to now cover diameters of 50, 63 and 80mm (or 2–3”) with the addition of the new M5250 helical milling cutter. Walter’s latest generation of indexable insert milling cutters is characterised by high performance paired with process reliability.

This process reliability and performance is credited to features like the reinforced insert pocket and insert seat.

What’s more, each individual tooth on the M5250 is cooled separately. Walter uses proven, double-edged BC 1605 system inserts on the face of the M5250 and this allows users to choose between various corner radii, cutting tool materials and six geometries.

The G51 geometry (‘The quiet one’) is perfect for applications that are likely to incur vibration or for tools with long projection lengths.

Reliable, robust & accurate sensors for mobile machinery

Mobile machines such as aerial work platforms, loader cranes and other construction vehicles and equipment with tough motion control applications demand robust sensors which deliver high precision and optimum reliability.

To meet these challenges sensor specialist BAUMER continues to expand its range of options with the introduction of a new safety compliant inclination sensor the GIM600R. The GIM600R sensor has been specifically designed to ensure maximum robustness combined with high measurement accuracy according to the latest standards (ISO138491:2023). The result is outstanding robustness and durability helping engineers simplify machine design, enabling higher performance in construction vehicles thanks to reliable measured values for static stability control.

The freeware Baumer Sensor Suite can also be used for the GIM600R providing parameterisation in an intuitive dashboard, saving even more engineering time.

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Manufacturing & Production Engineering Magazine

Latest Product Launches The G51 geometry (‘The quiet one’) is perfect for applications that are likely to incur vibration or for tools with long projection lengths. In contrast, the G55W cutting inserts with the Walter WaveCut geometry are ideal for titanium components with a high machining volume such as those commonly found in the aerospace industry. Walter uses milling cutter-specific SC 1105 cutting inserts with four cutting edges as peripheral inserts.

In addition to steel, cast iron and materials with difficult cutting properties, the helical milling cutter is also suitable for aluminium and other non-ferrous metals. Unlike other fully effective helical milling cutters, the Xtra·tec® XT milling cutters can also be used for full slotting alongside shoulder milling, pocket milling and ramping.

As well as flexibility and process reliability that is partially credited to the remarkable operational smoothness of the milling cutter, Walter emphasises the high machining volume results from the fully effective design of the milling cutter and the reduced process costs. These lower costs are the result of the two or four useable cutting edges per indexable insert. It is also the result of the new wear-resistant Tiger·tec® cutting tool materials that can be used. This ensures that beyond the aerospace industry, the M5250 offers extensive benefits for the general mechanical engineering sectors too.

The freeware Baumer Sensor Suite can also be used for the GIM600R. More at: https://www.baumer. com/gb/en/products/baumersensor-suite/a/baumer-sensorsuite OEM’s who have previously relied on the proven Baumer inclination sensors GIM140R or GIM500R can simply replace them with the new GIM600R and so benefit from enhanced performance safe in the knowledge that their systems are compliant with very latest safety standards.

More at: GIM600R | Baumer international

The ‘quick Schwanog change’ design of Drilling the inserts results in less time spent System changing inserts.

Takes Centre Stage to suit the end users’ application requirements, providing flexibility to accommodate a host of machine tools and application types.

Now available from Floyd Automatic Tooling is the new Schwanog interchangeable indexable centre drilling system.

Developed to significantly improve productivity, precision levels and positioning of drilled holes, the new centre drill system is perfect for preventing drills from drifting and maintaining a chamfer on the drilled hole.

Suitable for everything from one-offs to high-precision series production runs, the new Schwanog Centre Drilling system ensures consistently high surface finishes, tool life and performance.

Furthermore, the impressive new Schwanog Centre Drills provide a high repeatability of ±0.01mm for insert changeovers which is credited to an innovative insert pocket seat that securely locates and clamps the insert with astounding precision and stability. The tool body is available in a range of lengths and diameters

The ‘quick change’ design of the inserts results in less time spent changing inserts – giving you and your machine shop greater machine utilisation rates. Schwanog claims that when combined with the innovative tool geometry, the rapidchange system on this new drilling system guarantees a 40% increase in productivity.

The Schwanog Centre Drill designs range from a 60 to 140-degree point angle and depending on the material to be machined, a wide variety of carbide grades and coatings can be applied. This expansive selection of carbide grades and advanced coating technology ensures that the Schwanog Centre Drills are perfect for all application types on a wide variety of materials from aluminium, brass and copper through to steel, stainless and heat-resistant aerospace grade alloys such as Inconel and titanium.

For further information, please contact Floyd Automatic.

Manufacturing & Production Engineering Magazine

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Sustainability

‘For truly sustainable wind power, we need to extend the lifespan of turbines’ Tony Morgan, applications engineering manager at BGB, says that a booming aftersales market in the wind industry is key to its sustainability.

One of the biggest criticisms levelled at the wind industry is that, while the energy produced from wind turbines is clean and renewable, it isn’t truly sustainable due to the challenges around disposing of the decommissioned blades. Even though 96% of a wind turbine can be recycled, the fibreglass blades cannot – and their sheer size makes reports of them piling up in landfills particularly alarming.

The industry is well-aware of the challenge, and we’re already seeing a number of ambitious start-ups developing energy-efficient ways of breaking down the blades to extract the glass fibre from old turbines so it can be reused.

But, as with products in other industries, extending the lifespan of wind turbine blades beyond the usual 20 to 25 years is key to lowering their overall environmental impact

almost any turbine and feature in our new developments.

Maintenance isn’t just about patching up old turbines, though. For us, at BGB, it’s part of a bigger drive towards a circular economy which many of our customers now look for in their suppliers.

particularly as resources, including raw materials and energy, become scarcer. It’s also far less costly than replacing an entire turbine, and significantly reduces the installation challenges.

In fact, recycling entire wind turbines should be considered the final step once it’s no longer environmentally sustainable or commercially viable to remanufacture them, or if they’re not performing well enough.

Operators recognise this, which is why we’re seeing burgeoning demand in the spares and repairs aftermarket; a landscape where many would rather replace parts such as slip rings, brush holders and rotary unions to keep blades turning for longer, at a more cost-effective rate.

Innovative new components are being developed too, including wind brush and holder systems made for aftermarket customers and OEMagnostic ones that can be applied to

We want to design out waste and pollution in the first place, and keep turbines in use for as long as possible.

So, along with the parts themselves, we also offer a spares and repairs service so that operators aren’t waiting for brand new components to be made and shipped in, all of which could lead to lengthier periods of costly downtime.

Specialist testing facilities play a crucial role in the maintenance ecosystem, too. The ability to test out components, like slip rings, in simulated extreme heat or icy conditions, reassures operators that their turbine’s performance will be optimised and that it won’t break down if they choose to replace rather than build or buy new. Engineers are also able to access performance data in real-time, either on the ground at our Grantham headquarters or remotely, so they can make the most informed business decisions on precise data readings.

In a recent case, a customer came to us requiring a 19-year product lifetime guarantee. Our vigorous testing capabilities and sound knowledge of the wider market, however, demonstrated that we could, in fact, potentially double that requirement – even when considering some of the caveats associated with accelerated endurance testing. That’s a phenomenal achievement when you think that a single turbine can produce electricity for 1,500 average households per year.

The new Labour government has pledged to make Britain a ‘clean energy superpower’ and, of course, the wind industry is critical in helping to achieve this. By their nature, wind power operators and their suppliers are committed to finding sustainable solutions to the current challenges they face – otherwise their clean energy business model would be flawed. However, the growth of the aftermarket is a clear sign that they’re already taking action.

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Great British

Marketing

for Great British

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It’s this approach to customer service that has positioned M4M as THE go-to agency for ambitious manufacturing businesses.

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Events & Awards News

3D printing helps young entrepreneur’s therapy device blossom Entrepreneur and winner of Innovate UK’s 2023 Young Innovators award, Orlando Ely, has turned to additive manufacturing, better known as 3D printing, to bring a device that could revolutionise the way people recover from strokes and cognitive impairment a significant step closer to launch.

The therapy tool, called Blossom, was designed by Orlando after two close family members suffered strokes and, as part of the rehabilitation process, required a tool to improve and practice their fine motor skills in a creative and engaging way.

He is now developing a 3D-printed prototype of the nature-inspired product in collaboration with the National Manufacturing Institute Scotland

(NMIS), operated by the University of Strathclyde and part of the High Value Manufacturing (HVM) Catapult, which has been tested in clinical consultation and by users from dementia groups. The project was also supported with £15,000 of funding from Innovate UK. Blossom is a hand-held therapy device featuring three buildable flowers designed to challenge fine motor skills and enhance cognitive function.

Users can practice arranging the petals and stamen, with each flower increasing in difficulty. Its design, incorporating various petal layouts, encourages users to engage both hands and utilise 16 different pinch and grasp exercises. Blossom uniquely offers the evidence-based benefits of patterns, a re-connection with nature, and a creative outlet, all of which boost mood and motivation.

The NMIS Design Engineering and Additive Manufacturing teams provided comprehensive support to Orlando, transforming his vision into a viable product through detailed 3D modelling to optimise the design. This included evaluating and selecting appropriate materials and manufacturing processes to achieve the desired appearance and functional requirements.

AFRC achieves world-class accreditation for mechanical testing The University of Strathclyde’s Advanced Forning Research Centre (AFRC), part of the National Manufacturing Institute Scotland (NMIS), has added another internationally recognised accreditation to its name, having attained ISO 17025 for its mechanical testing laboratory.

This achievement underscores the centre’s commitment to continuous improvement and meeting the high-quality standards expected by the businesses from the UK and internationally that it helps to overcome manufacturing challenges and become more competitive.

Awarded by the United Kingdom Accreditation Service (UKAS), the AFRC, which is also part of the High Value Manufacturing (HVM) Catapult has secured the gold standard for four mechanical testing techniques. ISO 17025 is widely acknowledged as the benchmark of excellence for testing and calibration laboratories, focusing heavily on technical competence.

Notably, the centre has become the first in the UK to be accredited for elevated compression testing up to 1100°C as per the National Physical Laboratory’s good practice guide. It has also achieved accreditation for its standards in room temperature compression testing, room temperature tensile testing, and elevated temperature tensile testing up to 1000°C. With numerous years of industry experience, the AFRC’s mechanical testing team demonstrated its technical competency throughout the rigorous benchmarking process.

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Manufacturing & Production Engineering Magazine

Babcock Wanson UK Expands Environmental Solutions with DCT Regenerative Oxidisers & Solvent Recovery Systems

+44(0)151 356 2322 www.rotechsystems.co.uk sales@rotechsystems.co.uk

Following the acquisition of Donau Carbon Technologies (DCT) by the Babcock Wanson Group in 2022, industrial process heating equipment and solutions specialist Babcock Wanson UK has expanded its range of regenerative oxidisers and is now able to offer complete solvent recovery systems to help reduce customers’ carbon foot print and meet increasingly stringent emission limits for solvents and volatile organic compounds (VOC).

DCT solvent recovery systems feature activated carbon adsorption, using steam or inert gas for the regeneration.

A distillation section (batch or multi-columns) allows for a very high level of purity – frequently exceeding international standards - for the recovered solvents to then be reused in production, making for a rapid return on investment.

These solvent recovery systems are easy to use and, because they are modular, can be expanded and reconfigured to meet changing site requirements.

Rotech End of Shaft or belt driven units are used for monitoring: - Stop/slip - Underspeed/overspeed - Interlocking/sequencing

- Distance/direction - Rotation control - Belt weighers

For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.com or go to www.babcock-wanson.com

Totalkare’s ergonomic positioners are single or double column devices that enable the lifting and rotation of a product during welding and assembly operations.

With overall capacity from 2,000 - 90,000kg to suit, they are both compact and flexible.

GET A QUOTE: T:0121 585 2724 / WWW.TOTALKARE.CO.UK

Manufacturing & Production Engineering Magazine

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Asset Finance

View of the Manufacturer…

Three times a year Close Brothers Asset Finance conducts a wideranging survey of business owners across multiple sectors, including Manufacturing – here are just some of our findings from our recent research…

19% don’t foresee any significant changes.

Finance

Manufacturing firms’ top 10 main business concerns are, in order:

The most popular source of financial support and advice for manufacturers is their Financial Advisor (31%), followed by their Accountant (26%) and their Bank Manager (21%). Bottom of the list is their peers at just 2% 69% of manufacturing businesses plan to seek funding for business investment in the next 12 months.

14% of manufacturing firms have been declined access to finance in the past six months, while 29% have missed a business opportunity due to a lack of available finance.

Nearly half (48%) agree that taking out funding to protect cashflow is a good business strategy.

Nearly two thirds of manufacturing firms already use – or would consider using – an ‘alternative funder’.

The five most popular forms of funding are:

• Bank loans • Credit cards • Invoice finance • Overdrafts • Finance lease If respondents were to take out finance in the upcoming year, they would spend it on:

• Investing in new assets • Protecting cashflow • Stockpiling supplies • Improving current business premises • Paying overheads • Employing additional staff • Moving to a new premises • Mergers and acquisitions, or Management Buy Outs

Outlook Asked about the UK’s economic prospects, 42% of business owners are confident the economy is set to grow compared to 39% who are of the opinion it’s going to slow down; the remaining

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Manufacturing & Production Engineering Magazine

A third of participating company bosses think their firm will expand in the coming months. Only 7% say they will contract – the remainder will ‘stay the same’.

• Energy costs • Materials supply • Inflation • Interest rates • Cash flow • Lack of skilled staff • Late payments • Tax / VAT • Competitors • Managing expansion Their primary business priorities are:

• Achieving growth • Developing products/services • Investing in staff • Survival • Business consolidation • Paying down debts

Late payments Late payments are an issue for 38% of manufacturing businesses, with the majority owed between £20k and £40k.

Over a third say late payments are more of an issue today than a year ago.

Recruitment When it comes to being able to recruit adequately skilled staff, 48% are concerned about the skills gap in their sector; a further 19% have the same concern, but about their region. The rest don’t think there’s a problem.

Late payments are an issue for 38% of manufacturing businesses, with the majority owed between £20k and £40k.

Open Banking 55% know what ‘open banking’ is – 35% do not and the rest are unsure. Another 46% are confident they know how it works and 38% can see the benefits.

Events Three out of five manufacturers attend industry events as a visitor while 48% exhibit, with 70% of the opinion events have an important role to play in showcasing the sector.

Nearly four in 10 think it would be detrimental to manufacturing if events were no longer held.

Cost of attendance is an issue for 43% of respondents.

Cost of doing business 75% of manufacturers have been impacted by the rising cost of doing business, with 56% saying it’s negatively impacted their cash flow.

71% have seen their business insurance rise, necessitating 89% (23% completely; 66% partially) to pass these additional costs onto their customers.

The top five inflationary pressures they’ve felt are:

• Energy (gas, electricity) • Supplier costs • Interest rates • Fuel (petrol, diesel) • Rent

For more information please visit: closeassetfinance.co.uk/mpe

What is Asset Finance?

Very simply, it allows businesses of all sizes to get the equipment, vehicles and machinery they need. All without having to pay the full price upfront.

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Close Brothers Asset Finance is a trading style of Close Brothers Limited. Close Brothers Limited is registered in England and Wales (Company Number 00195626) and its registered office is 10 Crown Place, London, EC2A 4FT.

Technology & Software

The new age of sustainable abundance: how AI technologies are transforming manufacturing

By Simon Bowes, CVP Manufacturing Industry Strategy EMEA at Blue Yonder The UK’s manufacturing industry continues to face significant challenges around the profitable operation of its supply chains.

Continued geopolitical disruptions, rising costs, labour shortages, and sustainability pressures are all contributing to these uncertain conditions. However, as the UK economy begins to recover, manufacturers are turning their attention to innovative technology solutions to transform this vitally important sector and reimagine the supply chain.

Before the emergence of ChatGPT, AI was used for demand forecasting in manufacturing and supply chain. Predictive AI and algorithms have provided unique demand projections, including calculated business impact and risk which has allowed UK manufacturers to achieve higher planner productivity, better inventory management, and more understanding of demand drivers and customer behavior.

Generative AI allows manufacturers to learn from existing data and accelerate data-driven decision-making by delivering predictive insights, guided recommendations and automation without the hassle of wrangling data

Advanced cloud data solutions, like Snowflake, allow companies to break down data silos by digesting and analysing real-time insights from across the extended supply chain network, as well as third-party sources. Furthermore, cognitive solutions built on a modern SaaS native platform can use AI to evaluate many alternative plans very rapidly by harnessing the power of the data cloud. With an adaptable and eventdriven framework, these solutions transform how companies can tackle uncertainty in their supply chain management.

A sustainable future

or toggling between applications. This gives them the potential to significantly reduce lead times and predict market trends months ahead with precision.

The promise of artificial intelligence (AI) and machine learning (ML) has compelled many organisations to invest in new technology, running on data management platforms like Azure, to optimise and automate business processes, drive better performance, and increase profitability. Advanced technologies such as AI/ML depend on data for their success. Unless companies equip themselves to digitally capture and apply real-time data, on-demand changes, inventory levels and product availability, and other key factors, their advanced supply chain solutions will never reach full potential.

When AI is woven into the fabric of supply chains, manufacturers can cut costs and increase productivity – all while reducing their carbon footprint.

AI-enabled supply chains can help businesses to operate responsibly and profitably via reduced waste, more efficient production, smarter transportation strategies, reduced resource consumption, and circular stewardship practices. One way to promote environmental stewardship is by achieving a truly autonomous supply chain in which disruptive events, including sustainability issues, are sensed and addressed in realtime without human intervention. But the true power of digitalisation and AI lies in its ability to reach beyond the four walls of the business. It’s the whole supply chain that matters.

Shared sustainable decision-making across the supply chain, and all its suppliers’ suppliers is essential, and this is probably the biggest challenge for manufacturing businesses today. A truly sustainable supply chain should be connected, collaborative, circular and self reporting.

Reimaging the supply chain Advanced solutions for manufacturing not only increase real-time visibility and alert all stakeholders to disruptions, but they also ensure that the right decisions – ones that strategically balance cost, service, sustainability, and other considerations – are made every time.

Further, they enable an immediate, automated response that matches the dynamic business environment that is taking shape across the supply chain.

As the evolution of predictive AI, generative AI, cloud data platforms, and robots continues, manufacturers are set to increasingly rely on these technologies to power their organisation’s future success, in what we might call a new age of sustainable abundance.

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Manufacturing & Production Engineering Magazine

Expert Partner in Hygienic Solutions

Store street

A shoes and

don hygienic outerwear

Providing hygienic furniture and equipment for every stage of the changing room process, our innovative designs speed up the changing room flow and increase clean down efficiency.

We break down some of our key hygienic design aspects below:

DIRTY

Create the ultimate changing room flow

The A to B of the changing room flow

B Wash hands

C Dry hands

Joins & Welds We use seamless welding techniques, such as electrochemical weld cleaning, to create smooth joins that eliminate crevices where dirt, bacteria and contaminants can accumulate.

D Dispose of paper towel in waste bag holder

Sloped surfaces

E Grab your shoes from the shoe rack

Where possible, we have removed unnecessary flat surfaces where organisms can accumulate in favour for sloped tops. This small change to our cabinets, lockers and wash troughs makes a big difference in the fight against bacteria.

F Put on PPE (gloves, hairnets, beard snoods)

Materials

Check your

G gowning is

The majority of our furniture, equipment and accessories are made from 304L-grade stainless steel with the option to upgrade to 316L on request. This ensures that our products can withstand stringent hygiene processes with high chemical and corrosion resistance.

H Boot wash to reduce external dirt

I Turnstile entry with hand sanitisation

Expert Partner in Hygienic Solutions

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Call now on +44 (0)1603 788 833, visit teknomek.co.uk or email mail@teknomek.co.uk

correct before entering the production area.