Page 1

Manufacturing North America









Issue | 100


Auto industry

Unitech Aerospace


Tomorrow’s smarter, connected auto industry requires investment

A recent rebranding has unified the five divisions within the Group

Workplace trends are emerging that will have significant results


Manufacturing North America

Issue | 100



| Contents







Issue | 100


Unitech Aerospace


A recent rebranding has unified the five divisions within the Group

Workplace trends are emerging that will have significant results


Auto industry Tomorrow’s smarter, connected auto industry requires investment






t t Artwork

Global technology IHS Markit’s top seven global technology predictions for 2017

requires investments today


Investment $1.33 billion is being invested into Toyota’s Kentucky manufacturing facility, as part of its plan to invest $10 billion dollars in the U.S. over the next five years

News and views from across North America

Interviews and case studies


Unitech Composites


Paul Fabrications Ltd


Tods Aerospace and Tods Defence


North Coast Composites Tool and Mold


Suncor Inc


Twin Disc


Marketing & Engineering Solutions






Wall Colmonoy Ltd


Tele-Fonika Kable




Profiles Unitech Aerospace




© 2017 Manufacturing North America

Six trends to watch Workplace trends are emerging that will have significant ramifications for employers and job seekers

10/ 16


The Internet of Things IoT heading for mass adoption by 2019 driven by better-thanexpected business results

Auto industry Syntel CEO says tomorrow’s smarter, connected auto industry


Analysis and insights


Lead Features

Please note: The opinions expressed by contributors and advertisers within this publication do not necessarily coincide with those of the editor and publisher. Every reasonable effort is made to ensure that the information published is accurate, and correct at time of writing, but no legal responsibility for loss occasioned by the use of such information can be accepted by the publisher. All rights reserved. The contents of the magazine are strictly copyright, the property of MNA, and may not be copied, stored in a retrieval system, or reproduced without the prior written permission of the publisher.

30 42 1

Be part of the future A

IoT heading for mass adoption by 2019 driven by better-thanexpected business results 2

new global study ‘The Internet of Things: Today and Tomorrow’ published by Aruba, a Hewlett Packard Enterprise company, has revealed that Internet of Things (IoT) will soon be widespread as 85% of businesses plan to implement IoT by 2019, driven by a need for innovation and business efficiency. While the analysis confirms the clear business benefits from

investments in IoT, Aruba’s report cautions that connecting thousands of things to existing business networks has already resulted in security breaches for the majority of organizations. The research questioned 3,100 IT and business decision makers across 20 countries to evaluate the current state of IoT and its impact across different industries. The study shows that while virtually all

The Internet of Things

sensors connected to the Internet and behaving in an Internetlike way by making open, ad hoc connections, sharing data freely and allowing unexpected applications, so computers can understand the world around them and become humanity’s nervous system.”

The Expectations Dividend When examining the business benefits of IoT, Ashton discovered that the real-world benefits gained from IoT exceeded even the original expectations. This ‘expectations dividend’ is evident in two key performance areas: business efficiency and profitability.

levels of IoT maturity across different industry sectors. The following five vertical industries are leaders in their adoption of IoT and have realized tangible business benefits from a focused, use case approach to adoption. Enterprises create a smart workplace for productivity and efficiency: Over seven in ten (72%) enterprises have introduced IoT devices into the workplace. Indoor location-based services ranks as the second most promising use case to improve employee productivity, after remote monitoring. Twenty percent report remote operation of building lighting and temperature as a key


With the business benefits of IoT surpassing expectations, it’s no surprise that the business world will move towards mass adoption by 2019

business leaders (98%) have an understanding of IoT, many are unclear of the exact definition of IoT and what it means for their business. In his new eBook ‘Making Sense of IoT’, commissioned by Aruba, technology visionary Kevin Ashton—who coined the term ‘Internet of Things’— presents the following definition: “The ‘Internet of Things’ means

As an example, only 16% of business leaders projected a large profit gain from their IoT investment, yet post-adoption, 32% of executives realized profit increases. Similarly, only 29% of executives expected their IoT strategies to result in business efficiency improvements, whereas actual results show that 46% experienced efficiency gains. Chris Kozup, vice president of marketing at Aruba, comments: “With the business benefits of IoT surpassing expectations, it’s no surprise that the business world will move towards mass adoption by 2019. But with many executives unsure of how to apply IoT to their business, those who succeed in implementing IoT are well positioned to gain a competitive advantage.” 

How global organizations are using IoT Aruba’s research reveals varying

use case, but that number more than doubles to 53% when asked about future IoT implementations. Looking at the tangible results being realized today, 78% say the introduction of IoT in the workplace has improved the effectiveness of their IT team, and 75% find it has increased profitability.


The industrial sector increases business efficiency and visibility through IoT-enabled monitoring and maintenance: More than six in ten (62%) respondents in the industrial sector have already implemented IoT. Using IoT to monitor and maintain essential industrial functions was identified as the most impactful use case in the sector. Today, the use of IPbased surveillance cameras for physical security within industrial organizations is still in its infancy, with only 6% having implemented

l 3

it. However, when asked about future implementations, surveillance jumped five-fold to 32%. l Across the sector, 83% report increased business efficiency and another 80% have found improved visibility across the organization. Healthcare introduces IoT to improve patient monitoring, reduce cost and foster innovation: l Coming in as the third most advanced in its implementation of IoT, 60% of healthcare organisations globally have introduced IoT devices into their facilities. l Across the sector, 42% of executives rank monitoring and maintenance as the number one use of IoT—higher than all other sectors. This underscores the importance of IoT-enabled patient monitoring in the modern healthcare industry. Eight in ten report an increase in innovation and another 73% report cost savings.


Retailers engage with customers and boost sales using indoor location technology: l Just 49% of retailers are using IoT technology, but 81% of these report improved customer experiences. An improved customer experience is likely to have a significant impact on customer loyalty and ultimately, revenue. l In-store location services delivering personalized offers and product information to shoppers was touted as the number one implementation for IoT, alongside monitoring and maintenance. Four in ten retailers ranked surveillance in their top three key use cases. Governments lag in IoT adoption, struggle with legacy technology but still reduce costs: The slowest sector to adopt IoT, only 42% of municipalities have deployed IoT devices and sensors. A third (35%) of IT decision makers



claim their executives have little to no understanding of IoT, double the global average, suggesting that lack of education is the biggest barrier to mass adoption in this sector. l While nearly half (49%) of government IT departments are struggling with legacy technology, seven in ten IoT adopters in the

public sector report cost savings and improved organisational visibility as the major benefits.

The data context and security challenge Alongside these positive returns, the study also uncovers a number of obstacles that IT leaders feel are preventing

The Internet of Things

IoT from delivering greater business impact. In particular, the cost of implementation (50%), maintenance (44%) and integration of legacy technology (43%) were highlighted as key issues. Most notably, security flaws were found across many IoT deployments. The study found

that 84% of organisations have experienced an IoT-related security breach. More than half of respondents declared that external attacks are a key barrier to embracing and adopting an IoT strategy. This confirms that a holistic IoT security strategy, built on strong network access control and policy management, will not

only protect enterprises but also simplify the security approach for IT. The ability to capture and effectively use data is described by Kevin Ashton as “what defines the Internet of Things”, but this appears to be another clear challenge for global organizations. While nearly all (98%) of organisations that have adopted IoT claim that they can analyze data, almost all respondents (97%) feel there are challenges to creating value from this data. Well over a third (39%) of businesses are not extracting or analyzing data within corporate networks, and are thereby missing out on insights that could improve business decisions. Kozup comments, “While IoT grows in deployment, scale and complexity, proper security methodologies to protect the network and devices, and more importantly, the data and insights they extract, must also keep pace. If businesses do not take immediate steps to gain visibility and profile the IoT activities within their offices, they run the risk of exposure to potentially malicious activities. Aruba is enabling customers to rapidly assess IoT deployments within their facilities and determine any potential threats that may be present.” Ashton concludes: “Since its inception in 1999, the Internet of Things has been ridiculed, criticized, and misunderstood. And yet here we are, less than two decades later, in a world where tens of thousands of organizations are saving and making hundreds of millions of dollars from the Internet of Things, using cars that drive themselves, subway stations that sense passengers, algorithms that diagnose deadly diseases using phones, and many other once apparently-impossible technologies. The future promises far more amazing things. The most important decision you can make now is how to be a part of it.” M 5

Working in style

Workplace trends are emerging that will have significant ramifications for employers and job seekers alike, as AllisonTaylor highlights


Six trends to watch

While compensation pay has traditionally been a leading prerequisite for all job seekers, a desire for workplace flexibility has risen dramatically in importance. Yet, it is estimated that only a third of global corporations offer such flexibility. Of those that do offer at least some degree of workplace flexibility, many are not promoting this benefit to job seekers who increasingly spend more time researching companies before applying for new employment. This suggests a considerable opportunity for companies to not only increase their degree of workplace flexibility, but to market this benefit more aggressively to prospective new employees. There are several components to overall work flex, which include: l Working from the home, facilitated using new technological tools l Elimination of strict office hours l Adoption of “casual days” with reduced formal business attire

2. New internal communications tools replace email.


key theme is employee demand for a more flexible working environment that will allow greater latitude for a “work/life balance”. Employers wishing to attract – and retain – new talent will need to be mindful of this general trend, as well as the need to utilize newer, nontraditional tools such as instant messaging, people analytics, etc. Another key trend: reference checks will be vetted differently than in the past, with supervisory references gaining increasing prominence. Some specific trends we expect to see emerging include:

1. Workplace well-being becomes critical for attracting new talent.

As highly tech-savvy employees enter the marketplace, businesses will utilize more efficient internal communication tools such as text messaging, live chat and instant messaging, which will increasingly replace traditional emails.

3. Blended workplaces become increasingly predominant. The use of blended workforces, where freelance workers team up with full-time employees on project collaboration, is on the rise. An estimated 40% of workforces will be composed of freelancers in the next few years, reducing corporate benefits/health care costs. By necessity, these freelancers will need to interact more frequently with full-time employees than previously.

4. The reference checking

process takes an unconventional turn. A significant change in the reference checking process is that employers are more likely to call a job seeker’s former supervisors, rather than follow the traditional route of contacting Human Resources. This is because employers have concluded that former supervisors tend to be far more talkative about previous employees than Human Resources – and a talkative, knowledgeable reference is exactly what they seek. Related to this, a 2014 survey by the Workplace Bullying Institute ( identified 27% of responders as having current or past direct experience with abusive conduct at work. Bosses constituted the majority of bullies.

5. References become a powerful extension of a job seeker’s resume. A strong resume is only part of the employment equation. Employers look to references to provide critical employment information, and a wise job seeker should treat their references as a powerful extension of their resume. References should be chosen careful, and job seekers should have a cultivated list of references readily available (in a similar format/font as their resume) to be given to prospective employers.

6. Virtual reality tools revolutionize recruiting and training. Revenue from virtual reality hardware is projected to reach over eight billion (2014-2018). It is likely that employees experiencing this technology outside of work will ultimately desire similar technological tools at the office. Some companies such as General Mills already utilize a virtual reality tour of their offices as a tool to showcase the company to prospective employees at corporate job fairs. M 7

The year of tech

IHS Markit’s top seven global technology predictions for 2017


Global technology


rom artificial intelligence to the Internet of Things (IoT), far-reaching innovations are unfolding in virtually every technology sector around the globe, continuing to change the way consumers, businesses and machines interact while also spurring the next revolution in tech market growth, according to a new white paper from IHS Markit, a world leader in critical information, analytics and solutions for the major industries and markets that drive economies worldwide. For the white paper, IHS Markit surveyed its leading technology experts, who represent various industry segments including advertising, automotive, connected networks, consumer devices, entertainment, displays, media, semiconductors, telecommunications and others. These analysts were asked to provide their informed predictions for the global technology market in 2017. The Top Seven Technology Trends for 2017, as identified in this IHS Markit report and listed in no particular order, are as follows:

Trend #1 – Smart Manufacturing Accelerates With More Real-World Products Companies use IoT to transform how products are made, how supply chains are managed and how customers can influence design. l Example: look for automation/ operator tech firms to release their own Platforms-as-a Service (PaaS) offering in the cloud as they compete to offer and own IoT projects for the industrial market. l

Trend #2 – Artificial Intelligence (AI) Gets Serious Already, personified AI assistants from a handful of companies (Amazon’s Alexa, l

Apple’s Siri) have access to billions of users via smartphones and other devices. l However, even bigger, more profound changes are on their way as levels of human control are ceded directly to AI, such as in autonomous cars or robots.

Trend #3 – The Rise of Virtual Worlds After several years of hype, the operative reality behind virtual, augmented and mixed digital worlds is set to manifest more fully in 2017. The technology for augmented reality (AR) and virtual reality (VR) will advance significantly as Facebook, Google and Microsoft consolidate their existing technologies into more exhaustive strategies. l New versions of VR-capable game consoles featuring 4K video and high dynamic range (HDR) will also create the medium for high-quality VR content, even if availability will be limited for the next few years. l

Trend #4 – The “Meta Cloud” Era Arrives Communication service providers plan to deliver a new wave of innovation, allowing for a single connection to the enterprise and acting as a gateway to multiple cloud service providers. IHS Markit refers to this as the meta cloud. l In 2017, new offerings will become available from traditional Software-as-a-Service (SaaS) vendors, coupled with expanded offers from the likes of IBM, Amazon and most notably Google via its Tensor chip. Watch for the development and deployment of more specialized silicon in the next two years. l

Trend #5 – A Revolution in New Device Formats The development of the consumer drone is the closest example of a product type evolved over the past few years l

that has quickly gone mass market. 3D printers and pens are heading the same way. l The next set of new devices may well materialize at the boundary of cheap 3D printing and inexpensive smartphone components to create completely novel device types and uses.

Trend #6 – Solar Still the Largest Source of Renewable New Power 2017, will see photovoltaic (PV) technology retaining—and confirming—its position as the planet’s largest source of new renewable power. l More than a quarter of all PV capacity added worldwide in l

2016 and 2017 will be in the form of solar panels. The growth of solar can be attributed to sharp drops in the cost of PV systems, combined with favorable country policies toward new renewable power.

Trend #7 – Low-Power Technologies Extend Reach to Inaccessible IoT Devices The first batch of low-power, wide-area networks (LPWAN) will go live around the world in 2017 as an alternative to shortrange wireless standards such as Wi-Fi and Bluetooth. LPWAN technologies will connect hard-toreach, IoT devices more efficiently and at a lower cost, dealing with l

challenges stemming from range limitation to poor signal strength. As a result, opportunities will open up for telecom providers to support low-bit-rate applications. l In turn, the increased availability and low cost of LPWAN technologies will drive connectivity for smart metering, smart building and precision agriculture, among many other applications. To download the complimentary white paper, visit: M 9

Boom supersonic funding Boom Supersonic , the supersonic aircraft company, has announced its $33 million Series A round. Participants in the syndicate funding round include 8VC, Caffeinated Capital, Palm Drive Ventures, RRE Ventures, and Y Combinator’s Continuity Fund. The Series A brings Boom’s total funding to $41 million. Boom will use the new financing to finish development and fabrication of the XB-1 demonstrator and conduct a thorough flight test program including sonic boom testing. Y Combinator President Sam Altman and entrepreneur/investor Greg McAdoo have joined Boom’s board of directors. “Our mission is to make supersonic flight a reality,” said Blake Scholl, chief executive officer and founder of Boom. “With this new capital, we are closer than ever to the first flight of our XB-1 Supersonic Demonstrator in about a year.” “When I first met with Boom, I was fascinated by their plans to revive supersonic flight, making the world more accessible for millions of people,” said Sam Altman, President of Y Combinator. “Since then, Boom has formed partnerships with aviation industry leading manufacturers and made rapid progress in the development of the demonstrator – I am excited to be part of the coming supersonic renaissance.”

Ford expecting growth Ford sees the SUV segment growing further – accounting for more than 45 percent of the non-premium U.S. retail auto industry in the next five to seven years. Ford is well-positioned for this growth, with plans to add five all-new SUVs to its lineup in North America by 2020. Demographics are driving the anticipated trend, as more millennials and baby boomers favor the functionality and technology SUVs bring. “In the 1990s, SUVs defined the unstoppable American spirit, and once again, we’re seeing a utility boom take hold with a whole new generation of customers,” said Mark LaNeve, Ford vice president, U.S. marketing, sales and service. “Two sets of consumers – millennials and baby boomers – are driving this growth, and Ford will be ready with a full portfolio of SUVs to meet their needs.” Ford already has a full utility lineup – including the fun, capable and connected EcoSport, technology-packed Escape, stylish Edge crossover, all-new full-size Expedition that’s the smartest, most adaptable and capable ever, and now, the new Explorer that’s on its way. For 2018, Explorer has been further upgraded, providing customers freshened front and rear styling details, even better technology and more choice.

Boeing program plaudits Boeing will be recognized by the U.S. Environmental Protection Agency (EPA) with a 2017 ENERGY STAR Partner of the Year – Sustained Excellence Award for the company’s continued leadership in protecting the environment through superior energy efficiency. Boeing will receive the award April 26 in Washington, D.C. This is the seventh consecutive year Boeing has been recognized by ENERGY STAR. “We know that strong environmental performance is good for the planet and key to long-term business success. We are excited to build on the progress we have made and to further improve the efficiency of our products and our operations,” said Ursula English, Boeing vice president of Environment, Health & Safety. “In our second century, we’re aiming to be the most environmentally progressive company in the aerospace industry and to be a leader among our industrial peers.” Beverly Wyse, president of Boeing Shared Services Group, will accept the ENERGY STAR award on behalf of Boeing. “We’re thankful to the EPA for this recognition, but the greater thanks truly belongs to our Boeing employees who bring a strong commitment to environmental leadership to work with them every day,” said Wyse. “It is their inspiration and innovation that allows us to keep incorporating new efficiencies and energy conservation technologies into our processes and operations.” 10

News Atlas Copco first product roll out Atlas Copco has produced its first piece of equipment, the XAS 185 portable air compressor, at its new production facility in Rock Hill, South Carolina. Facility construction, which began in January 2016, included lean manufacturing features to enable efficient and flexible processes that are sustainable for the environment. The compressor is the first product of Atlas Copco’s wide range of equipment, including generators and stationary compressors, that will be produced at the plant, which officially opened in February 2017. “We have a continued commitment to the U.S. market,” said Scott Carnell, Atlas Copco U.S. president. “This commitment is more than our ongoing innovations in equipment design. It also involves being close to our customers, and our new facility helps us achieve that.” Atlas Copco built the facility to enhance its support for the North American construction market. The 180,000-square-foot plant is Leadership in Energy and Environmental Design certified and serves as the production and assembly facility for Atlas Copco’s North American Construction Technique division. Several Atlas Copco team members commemorated the event by signing the compressor as it exited the production line. The compressor will be a reminder of the hard work and dedication the entire Atlas Copco team puts forth to bring sustainable productivity to customers.

Apple in India According to a report from Reuters, Apple Inc will in the coming months start assembling its lower-priced iPhone SE models at a contract manufacturer’s plant in the southern Indian technology hub of Bengaluru. Apple’s Taiwanese manufacturing partner Wistron Corp is setting up a plant in Bengaluru to focus solely on assembling iPhones, a separate source told Reuters earlier in 2017. Apple’s move comes as it seeks to boost its share in the world’s fastest growing major mobile market, where handsets far cheaper than Apple’s iPhones dominate. It also comes as smartphone sales growth is slowing in Asia’s other massive market, China. To lower prices, Apple has been seeking to set up local production and has been in talks with the Indian federal government regarding issues such as tax concessions. The industry source told Reuters the initial manufacturing of the iPhone SE model was not contingent on those concessions. According to market researcher Counterpoint, Apple shipped 2.5 million iPhones to India last year, with a third coming in the December quarter.

Coca-Cola celebrates China partners The Coca-Cola Company has issued a statement congratulating its local bottling partners in China - COFCO Coca-Cola Beverages Limited (a subsidiary of COFCO Corporation) and Swire Beverages Holdings Limited - on the closing of the majority of refranchising transactions in Coca-Cola’s third-largest market. Following transactions closed on April 1, all Coca-Cola bottling territories in China are now majority owned by local franchise partners. “We congratulate COFCO and Swire on the closing of these important transactions and look forward to working together to fully complete the refranchising process in China in the coming months,” said Muhtar Kent, Chairman and CEO of The Coca-Cola Company. “COFCO and Swire will be able to leverage greater scale, capability and efficiency to invest for growth and deliver improved service to customers and consumers throughout China’s fast-changing marketplace. “COFCO Coca-Cola Beverages Limited and Swire Beverages Holding are led by Mrs. Xiuju Luan and Mrs. Karen So, respectively. We wish them and all 45,000 Coca-Cola system associates in China continued success as we move to our next phase of growth,” Kent continued. As announced when the parties reached a definitive refranchising agreement last November, Coca-Cola sees refranchising in China as a key milestone in positioning strong, local bottling companies for long-term success. 11

Automakers drive to modernize T Syntel CEO says tomorrow’s smarter, connected auto industry requires investments today 12

he automotive industry is being shaken up by technology advancements, which are impacting the future of the business. A PwC study revealed that electronics systems today contribute to more than 90% of innovations and new features in modern vehicles. Manufacturers are increasingly partnering with non-traditional players, such as software companies, in order to integrate innovative digital technologies into their products. Research by McKinsey asserts

that the vehicle of the future will be connected. Manufacturers will not only be able to monitor data in real-time for safety and reliability purposes, but vehicles themselves will communicate with other vehicles and an increasingly smart roadway infrastructure. The convergence of the Internet of Things (IoT), sophisticated new sensor and telematics systems, Cloud computing networks and Big Data analytics give automakers access to new streams of realtime data from vehicles, which can provide valuable insight into

Auto industry

potential for this technology, and the ability to efficiently handle, store and interpret massive amounts of vehicle data is the key to success.

“More and more, cars are becoming mobile technology hubs, and digital features are no longer just a fancy option, but a vital part of the vehicle itself,”

The customer experience is an ongoing process that really relies on staying connected with the consumer after the sale

both their products and their consumers. The continuing shift to more digital cars is being driven by ‘digital native’ customers who expect vehicles to act like smart devices, as well as mandates from the US Department of Transportation, which recently proposed new requirements for vehicle-to-vehicle (V2V) communication by the year 2020. According to Rakesh Khanna, Interim CEO and President of Syntel, manufacturers are still scratching the surface of the

“Throughout the various stages of a vehicle’s life span, from production through to the consumer, there is valuable data,” said Khanna. “Traditionally, most enterprises have stored their data in inflexible, isolated or ‘siloed’ systems which are a big hassle to maintain and make it hard to collaborate and analyze this valuable information to improve product and business performance. “Just pouring loads of new data into old storage systems is a recipe for disaster, as old database technology is unable to perform the type of analytics needed to provide the really valuable insight that creates advantage,” said Khanna. Khanna’s firm, leading digital modernization provider Syntel, offers a suite of services that enable manufacturers to convert and migrate their legacy data to modern platforms, where it can be unified and integrated with new data for analysis. By leveraging tools including the SyntBots® automation platform, Syntel enables manufacturers to quickly move from outdated mainframe data storage to more efficient, scalable Big Data systems, which has the potential to improve performance while reducing maintenance and support costs by as much as 30%. The results, according to Khanna, are higher quality products, greater customer satisfaction and the ability to create real value from this data.

he said. “Connected cars can send manufacturers important performance data that enables them to identify patterns and apply predictive analytics to detect faults or breakdowns before they happen.” Khanna says the benefits of this type of analysis are greater efficiency, better customer service, reduced warranty costs, improved vehicle safety, and the ability to apply real-time insights about vehicle performance to the design and engineering of future models. According to McKinsey, new technology-driven automotive features could add as much as $1.5 trillion in new revenue potential to the industry by 2030, even while the growth rate in vehicle sales drops. This makes it important for manufacturers to recognize the value of their existing customers and invest in creating a positive, lasting customer experience. “The customer experience is an ongoing process that really relies on staying connected with the consumer after the sale,” said Khanna. “At Syntel, we are working with a truck and commercial vehicle manufacturer to enable real-time monitoring of sensors embedded in more than 20,000 of their vehicles on the road today. “The system benefits their business in multiple ways, including more efficient operations, increased customer loyalty, and the ability to create a valuable cycle where the collected data today, helps build safer, more reliable vehicles tomorrow.” M 13

The future

is now


Toyota’s largest plant, with more than 8,200 team members, solidifies its commitment to U.S. manufacturing 14

$1.33 billion investment - the highest of any automaker in Kentucky and the second-largest in state history - will make Toyota Motor Manufacturing, Kentucky, Inc. (TMMK) the first plant in North America to begin producing vehicles using Toyota New Global Architecture (TNGA). Named the ‘Most American Made’ car by Cars. com and the number one selling car in America for the past 15 years, the Camry, from the 2018 model year, will become the first Toyota vehicle made in the U.S. to fully incorporate the new vehicle development and production technology.

“This $1.33 billion investment is part of Toyota’s plan to invest $10 billion dollars in the U.S. over the next five years, on top of the nearly $22 billion Toyota has invested in the U.S. over the past 60 years,” said Jim Lentz, CEO of Toyota Motor North America. “Toyota New Global Architecture is about exciting, ever-better vehicles for our customers as it will improve performance of all models, including increased fuel efficiency, more responsive handling, and a more stable, comfortable feel while driving.” TNGA represents a completely new strategy to the way the company designs, engineers,


and manufactures its vehicles. In addition, it will shorten the development cycle for vehicle improvements and new vehicles. TNGA retains all of Toyota’s traditional values of exceptional build quality and safety while injecting a fun driving experience with more responsive handling, regardless of the model. It also allows for a more flexible production environment, which will allow Toyota Kentucky to build ever-better cars, and respond quicker and more capably to customer demands down the road.

Major overhaul In addition to TNGA improvements, TMMK will undergo other makeovers that will, together, modernize and streamline the production process. That includes updating equipment and construction of an all-new paint shop. “This is the largest investment in our plant’s history and it speaks directly to the quality of our people and our products, as well as the partnerships we’ve forged in the local community and across the state,” said Wil James, president, Toyota Motor Manufacturing, Kentucky, Inc. (TMMK). “This major overhaul will enable the plant to stay flexible and competitive, further cementing our presence in Kentucky.” Toyota Kentucky is the automaker’s largest plant in the world, employing 8,200 team members. This represents an alltime high after recently adding over 700 people to support the upcoming launch of the 2018 Camry. Last year, TMMK produced nearly a quarter of the total number of Toyota vehicles produced in North America – over 500,000. In total, the plant has produced more than one-third – 11 million – of all Toyota vehicles manufactured in North America since 1986.

Toyota is a global icon. This $1.33 billion investment is further proof of its commitment to producing American-made cars American-made This announcement adds to the $530 million investment the plant committed to in 2013, in part to support Lexus production. This brings Toyota Kentucky’s investment in the last four years to approximately $1.86 billion. “Toyota is a global icon. This $1.33 billion investment is further proof of its commitment to producing American-made cars that are among the finest quality found anywhere in the world,” said Governor Matt Bevin. “It also serves as a testament to the hard work and dedication of the plant’s current employees, and reaffirms Toyota’s confidence in the advantages of manufacturing in Kentucky. We are grateful that this significant investment further validates the fact that Kentucky is the engineering and manufacturing hub of excellence in America.” “Today’s announcement is welcome news for Kentucky’s economy and our workforce,” Senator Mitch McConnell said. “For more than 30 years, Toyota has been committed to the Commonwealth, and today’s investment is further proof that the company maintains its pledge to grow our economy and solidify Kentucky as a worldclass automotive state. I want to congratulate the Toyota team, especially its thousands of hardworking Kentuckians.” A recent study by the Center for Automotive Research shows Toyota Kentucky supports nearly 30,000 jobs across the state (direct, indirect, and spin-off). TMMK employees live

in 80 Kentucky counties, and currently Toyota has more than 100 suppliers located across the Commonwealth. “Toyota is a great asset to Kentucky and the decision to continue its commitment to Kentucky jobs by investing in the Georgetown plant is wonderful news for the Commonwealth and a reflection of its confidence in Kentucky as a prime location for business growth and innovation,” said Senator Rand Paul. “I congratulate Toyota on this new initiative, and look forward to continuing my efforts in Congress to promote businessfriendly policies to ensure Kentucky continues to reap the benefits of economic growth and expansion as a result of these types of investments.” “This major investment further solidifies Toyota’s long-term commitment to its Kentucky plant,” said Secretary Terry Gill of the Kentucky Cabinet for Economic Development. “Its ripple effects will add to Toyota’s three decades of transformative impact on our communities and for our residents across the Commonwealth. Additionally, this strengthens Kentucky’s status as a top state for auto manufacturing.”

A community effort With the next chapter for the plant a bright one, Toyota is giving back to Scott County to help drive economic development efforts for the community. Three properties at Lanes Run Business Park, totaling nearly 22-acres, as well as $1 million for future land purchases, are being donated to further advance the vision for the area. Additionally, Toyota is committing $2 million over the next 10 years to Scott County United to go toward economic development initiatives that will benefit the community and region. M 15

North American Solutions Centre launched Renishaw has launched its first North American Additive Manufacturing Solutions Centre in Kitchener, Canada. The new facility provides a secure development environment where customers can gain knowledge and confidence using additive manufacturing technologies. The Solutions Centre is staffed with skilled applications engineers and allows customers access to additive manufacturing technology and expertise at a predictable, manageable cost. The new facility complements the established advanced manufacturing sector in Canada and will aid the acceleration of the development of industrial additive manufacturing processes, particularly in the medical and aerospace industries. The centre contains a range of Renishaw technology including the company’s AM250 and AM400 additive manufacturing systems, as well as metrology and finishing equipment. “The new Solutions Centre will provide North American customers with a cost-effective, rapid learning environment where companies can build confidence and knowledge in the applications of additive manufacturing,” explained Marc Saunders, Director of Global Solutions Centres of Renishaw. Mark Kirby, Renishaw Additive Manufacturing Business Manager added: “Renishaw’s knowledge of metrology, machining and finishing means that for a predictable cost the customer can move down the additive manufacturing learning curve with minimal risk.”

Building transformation The Atlantic Station Project will transform the old Stamford, CT Post Office building into a mixed-use development with spectacular views of Manhattan and Long Island. The complex comprises a dynamic retail and restaurant area set underneath two tower blocks reaching 21 and 29 storeys tall, respectively, as well as a car park for more than 800 vehicles. For projects such as these, the formwork employed must allow for rapid pouring cycles. The new formwork system FORMADECK provides all the speed necessary without compromising quality. It is designed to permit early equipment recovery, which can be rapidly assembled for the subsequent pour. FORMADECK’s rigorous safety standards don’t hinder its efficiency in the slightest. In fact, the pace of work is increased by the lightweight aluminum components that permit the system to assembled from the ground. ULMA supplied more than 5,500 m2 of formwork systems for one of the towers and the car park, including innovative solutions such as MEGALITE, the man-portable formwork system for walls and columns, and KSP Platforms, designed for lift shafts, stairways, and other confined spaces that require a formwork support structure.

$1 million investment for US expansion EnerQuip, designer and manufacture of torque machines and associated products, has announced the opening of a new facility in Houston following a growing demand for its products and services. The company has invested $1 million in this strategically positioned facility, EnerQuip Torque Solutions Inc. This new operation will improve response times directly into Canada and the Americas. The US Operation will complement the facilities in Aberdeen and Caithness, Scotland and is key to the success and growth of the company as it expands international sales and service support for any make and model of torque machine. EnerQuip envisages the Houston headcount will at least double in the next six months with jobs being created for service technicians and business development roles. Director, Andrew Robins said: “Houston is a key strategic market for us, whilst we have entered into it earlier than planned, this was driven by the successes we have had in the area. Our investment in Houston marks a firm commitment to the region and positive start to 2017. We will actively be employing staff locally to meet the demand in this area.” 16

News Miami venue for Forum TIACA has announced that its 2020 Air Cargo Forum (ACF) will take place in Miami, Florida, USA, and will be co-located with both Multimodal Americas and Supply Chain Americas. TIACA’s showcase biennial event brings together supply chain decision makers from across the globe for three days of networking and learning from the experts. “TIACA is the only association representing all segments of the air cargo supply chain and our ACF presents a unique opportunity for that community to get together to grow business,” said Vladimir Zubkov, Secretary General, TIACA. “Miami is a vibrant, world-class trade community at the crossroads of the Americas and we are delighted to be holding our 2020 event there.” The 2020 event will be held at the Miami Beach Convention Center, which is currently undergoing a $525 million renovation and is set to become one of the premier expo venues in the Americas. The 2018 ACF will take place from the 17th to the 19th of October at the Metro Toronto Convention Center in conjunction with the first Multimodal Americas show and in partnership with the Canadian International Freight Forwarders Association (CIFFA).

New acquisition announced JBT Corporation has acquired Avure Technologies, Inc. for $57 million, before post close adjustments. Avure is a leader in food processing technology and has gone on to create a range of HPP systems for worldwide tolling centers and major food manufacturers all over the globe. JBT Corporation, also a global leader in food and beverage processing solutions, has curated customer solutions up and down the line – from cooking, frying and chilling to portioning, sorting, weighing and grading in the protein market to extraction, mixing, blending, filling, closing and sterilization in the liquid foods market. And now, with the addition of Avure Technologies to the family, JBT is expanding its clean label solutions for fresh, flavorful foods and beverages with a longer shelf life. “With the expanding marketplace adoption of HPP technology as well as broad applications across both protein and liquid foods, the integration of Avure solutions into the JBT portfolio means we can now offer comprehensive thermal and non-thermal preservation solutions to global food and beverage producers,” explains Steve Smith, president, JBT FoodTech. “We’ll add our global salesforce and responsive aftermarket support to the development and installation of these HPP systems to create best-in-class lines for our customers.”

Sailing into new waters Fluid Mechanics, one of the USA’s leading servicers of fuel injection systems for maritime diesel engines has now become part of L’Orange, the German leader in electronically-controlled, high-pressure injection technology for diesel and heavy fuel oil engines. This year Fluid Mechanics celebrates its 60th anniversary and will continue in North America to use the same name and personnel but now as fully functioning operation of L’Orange, a Rolls-Royce Power Systems company. With all employees and the current management retained, Olav Altmann, Head of Sales at L’Orange, believes this will be the perfect starting point to expand in the maritime engine sector operating out of North America and sees the new operation as an ideal fit for both companies. “In China, we laid the foundations for the Asian market in 2009 with the opening of our office in Suzhou and now we are doing the same in the Americas with our long-term distribution partner in the US, building on our many years of experience with Fluid Mechanics and on its solid market presence.” 17

A unified


Operating as the parent company of five unified manufacturing businesses, Unitech Aerospace provides the aerospace, marine, medical, defence, nuclear and rail industries with composite and metallic structures and components that meet demanding and complex production requirements


mbodying more than 80 years of experience in the manufacture and assembly of high-quality composites and metallic components and aerostructures, Unitech Aerospace is a leading provider of build-toprint and design-build solutions for clients operating within the aerospace and defence industries. Unitech Aerospace is the parent company of Unitech Composites (Hayden, Idaho), North Coast Composites and North Coast


Tool & Mold (Cleveland, Ohio), Paul Fabrications (Derby, UK), Tods Aerospace (Yeovil, UK) and Tods Defence (Portland, UK), which allows the business deliver a comprehensive range of specialisations comprising: • Structural and non-structural composites laminates and assemblies • High standards of quality, on time delivery and lead-times • Fast turnaround in prototype manufacturing


| Unitech Aerospace

We also maintain virtually 100 per cent control of our manufacturing steps so that minimal outside processing needs to be performed

• Design, development, test and manufacturing expertise • Honeycomb core machining, forming and sandwich panel construction • Carbon fibre, fibreglass and Kevlar composites with multiple resin systems • In-house ultrasonic and x-ray non destructive testing (NDT) • Manufacturing and tooling engineering • Broad OEM and tier 1 approvals The business previously operated

under the name of AGC AeroComposites until February 2017, when it was announced that the decision had been taken to rebrand the company as Unitech Aerospace. Under this new branding the business continues to provide its established portfolio of services with a fully unified brand and direction. “We operate composites, tooling, resin transfer moulding and metallic-based businesses within our portfolio of companies. We felt that we should present to our various markets as a unified group and yet trade on our industrial heritage with the brand names that are well known and respected across our industry,” reveals Unitech Aerospace CEO, Wayne Exton. “For example Tods Aerospace is well known as a highly engineered composites provider. Going forward we plan to maintain the Unitech Aerospace parent company name and as we progressively grow both organically and by acquisition, we will maintain the core brand values inherent in our operating businesses.” Throughout the company, Unitech Aerospace maintains a strong core of values, which are further translated into the group’s processes and procedures. These processes are standardised across the business to allow each company within the Unitech Aerospace group to fully leverage the advantages of its operational procedures, while remaining committed to the local development of each division. “Our leaders can be focused on execution and growth and have significant autonomy to do what

is in the best interest of their business locally. We look for our leaders to be entrepreneurial and nimble,” Wayne elaborates. “Each of our businesses has a combination of unique manufacturing processes and specific customer and regulatory certifications to support the customer base.”

Highly efficient Unitech Aerospace boasts many years of industry experience of working with the manufacturing industry’s top OEMs and tier 1 companies across multiple platforms and programmes. These include military and commercial applications, while the company carries over 30 process and qualification specifications for composite, sandwich and bonding related work. These are further supported by a strict quality statement that is committed to delivering high quality products on time through the continued adherence to AS9100 and NADCAP guidelines. “We supply to most of the aerospace community as either a tier 1 or tier 2 partner. For example, we produce air-to-air refuelling pods for Cobham, complex fabrications for Rolls-Royce engines and the F-35 BOSS helmet for Rockwell Collins. We also manufacture multiple products for GE, Honeywell, Spirit, Boeing, Airbus, Triumph and others. We provide products for the commercial aircraft, business jet aircraft and military aerospace markets. We also provide sonar domes to various sovereign naval forces as well as prime defence contractors,” Wayne details. 19

“On the composite side, this covers the entire range of inautoclave to out-of-autoclave operations and RTM/VARTM capabilities to support the wide range of structural applications for our products and to create the most cost-effective basis for the end user. On the machining side, we possess a full range of machining applications ranging from forming capabilities to laser weld/drill and metal forming,” he continues. “We also maintain virtually 100 per cent control of our manufacturing steps so that minimal outside processing needs to be performed – this gives us the broader ability to continuously improve cycle time and cost yet also maintain our total quality expectations. We have embraced lean manufacturing principles to focus on waste


elimination, level loading, and high quality yield. Even our daily status boards have been standardised to drive common metrics, focus, and communication. Our end goal is an entirely visual factory providing our employees with the tools, planning parameters and capital investment to support the dynamics of the complex requirements of our clients.”

True partnership At any given point in time Unitech Aerospace has a number of exciting projects moving forward, which include technology applications using its advanced fibre-laser machine or its automated composite lay-up machine. These range from continued support to the company’s existing clients as well as the introduction of new

Unitech Aerospace

services to new clients, with details of the these projects being communicated through the Unitech Aerospace web-site and press releases. “Our competitive edge beyond our strong technical capabilities and track record is to develop a true partnership with our customers above the normal day-to-day business. This includes dedicated resources assigned to a project, joint-planning sessions to establish a future state capabilities matrix and capacity allocation, and finally a process agreement that streamlines everything from the commercial terms to the delivery parameters,” Wayne says. “We are continuously looking at new programmes and opportunities and we perceive significant potential for growth through partnership with our customers and are in the process

of developing several exciting new technologies.” With years of industry experience and a newly unified and strong industry brand, Unitech Aerospace is well placed to continue to deliver worldclass manufacturing solutions to its clients across a range of industry sectors. During the coming months and years, the

company will focus on increasing its position and service portfolio, while serving the needs of both new and existing clients. “Our vision for the future of Unitech is expanded capability to take on a higher level of support for our customers,” Wayne concludes. “This includes continually growing our engineering team into a world class developer of new technologies and the application of new materials as well as our methodology for creating manufacturing enhancements, sub-assembly to final assembly support and logistical control to provide a seamless interaction.” M

Unitech Aerospace Services: Complex composite and metallic manufacture 21

Components of

success Unitech Composites, a Unitech Aerospace Company, has over 35 years experience in the manufacture and assembly of high-quality composite components and aerostructures



| Unitech Composites 23

Unitech Composites


ark Withrow, Vice President & General Manager, began by explaining that today Unitech Composites is specialised in the production and creation of complex laminates and sandwich panels, as well as multi-axis machining, close tolerance fabrication and automated hand layup. “We serve the commercial and defence aerospace sectors, and we have establised a long standing reputation for quality, on-time performance, broad industry certifications and processes, low cost and agility,” he said. In fact, the manufacturer has numerous design platforms and a range of manufacturing technologies from which to choose and utilises over 80,000 square feet of manufacturing space in Hayden, Idaho (close to Spokane, Washington) allowing it to offer premium results throughout all phases of manufacturing. “We offer complete composite solutions with extensive manufacturing capabilities and a highly skilled workforce, and we have the ability to handle process specifications on a full spectrum of materials with a full suite of regulatory certifications,” Mark noted, when highlighting more of Unitech Composites’ skills and services. “What we provide is a low-risk, optimised solution, from a trusted lifecycle partner and we can work from conceptual design to full-rate production. “We were founded in 1979 and we have our roots in the NASA space programme,” he added, further highlighting the organisation’s exemplary pedigree. Today clients include companies such as Airbus, Avcorp, The Boeing Company, GKN, Honeywell, MD Helicopters, Northrop Grumman, Spirit Aerosystems, the US Army and many more companies both large and small. Many of these clients come to


Unitech Composites to utilise its expertise in autoclave processing, the hand lay-up of carbon fiber parts and automated hand layup. Indeed, the organization has recently invested in a state-ofthe-art automated hand lay-up machine, which produces quality superior to hand lay-up and offers increased mistake-proofing, consistent laminate thickness, elimination of bridging, voids and variability. “We are committed to investing in technology to support future state-of-the-art developments,” Mark highlighted. This new technology has been

added to the existing equipment used within the factory, which includes: • Six clean rooms • Three autoclaves (largest 15’ x 30’) • Four ovens (largest 24’ x 26’) • A self-contained machine shop and tooling manufacturing center • Complex composite ducts using eutectic salt and plaster mandrels • Three 4-axis Haas CNCs • Three 5-axis DMS CNC (largest 25’ X 10’) • Two 3-axis routers

Larkin Precision Machining Larkin Precision Machining started with a division of AGC called Integrated Composites in 2005 in Marina, CA. We started with some prototype components to join with composite structures to replace much heavier metal structures, mounted to Military Aircraft. As time went on, Integrated Composites was awarded multi-year production and shipping contracts. Eventually the division of AGC Integrated Composites was transferred to Unitech Composites. Today Larkin Precision Machining is very proud of the fact that it currently supports Unitech with titanium components for the F-35 aircraft pilots’ helmet. Larkin Precision Machining is a diversified company. Not only does it work in defense, it also has customers in the medical and food industries. It prides itself on being a small shop with big customers. The company recently obtained AS9100 and ISO9001 certifications that sets it apart from competitive businesses in the small shop category. Larkin Precision Machining is investing into its future with technology and automation. The milling department comes with state-of-the-art and high-speed CNC machining centres comprising of vertical and horizontal machining centres. A pair of palletised Matsuura H-Plus 405s with 30hp and 240 tools takes care of the horizontal side of things, while currently all of the verticals are Haas, including three new UMC-750 5-axis machining centers and six 3-axis verticals including a large 40” x 64” VF-8. The UMC-750’s have increased overall productivity and efficiency due to ease of set up, getting more done in one operation, and allowing operators to run multiple machines more efficiently. We want potential customers to know that we offer a lot more than some of our competitors. We always deliver quality products, above and beyond our customer’s expectations. We are looking forward to many more years supporting Unitech.

• In-house non-destructive testing (ATTU) • Laser ply placement • Automated ply cutting The full spectrum of materials in use at Unitech Composites include:

Prepregs • Polyester-glass • Phenolic-glass • Epoxy-glass • Epoxy-Kevlar® • Epoxy-graphite

Industri-Tech LLC Industri-Tech LLC has been a supplier and partner of Unitech Composites for approximately 32 years. We have watched Unitech grow internally and supported the company through its acquirement by AGC Aerospace. We have enjoyed growing along with Unitech and the relationships we have developed with the company’s people over the years. Richard McMillan and his team hope this relationship will continue to grow successfully for Industri-Tech LLC and Unitech.


Cores • Nomex®-Honeycomb • Aluminum Honeycomb • Klegecell® Foam • Urethane Foam These state-of-the-art technologies and materials are combined and used in the creation of products including: • Environmental Control System (ECS ducting) • Active Winglets • Brackets and Intercostals • F-35 BOSS Helmet • Edgebands • Weapons Pylons (Lightweight Armament Support System (LASS) and Multi Station Lightweight Armament Support System (MLASS) It is apparent from this list that Unitech Composites’ products are extremely sophisticated and

Unitech Composites

used in demanding applications that require the highest levels of quality and service. “This means we have to maintain constant communication with the customer,” Mark confirmed. “We are a totally customer-focused business and we have stringent quality reviews in place to ensure we always meet the needs of our clients.” He went on to give more details on specific products that perfectly illustrate the technical capabilties of Unitech Composites. “We developed the Binocular Optical Support Structure (BOSS) Helmet for the F-35, and we make this part for Rockwell Collins,” he said. “This is an extremely high precision composite/metallic structure for the helmet mounted heads-up displays. “We also developed weapons

pylons – the LASS and MLASSthat were designed to replace the legacy steel weapon pylon on the Blackhawk helicopter (UH-60). These are lightweight and corrosion resistant, but use the same installation kits and procedures. Made from a full carbon structure with aluminum

fittings, they offer 53 per cent weight reduction and meet all US Army service load requirements. These are currently in service with the US Army.” As it advances into 2017, Unitech Composites is in a strong position to build further success, and the recent rebranding of parent company AGC AeroComposites to Unitech Aerospace can only help to develop its reputation for performance, quality and value. “We feel that the market is strong and offers great opportunities for growth for our company,” concluded Mark. “We are optimistic about the future.” M

Unitech Composites Products: Composite products content/composite-manufacturing 27

Reliable reputation Founded in 1937, Paul Fabrications Ltd has provided precision manufactured complex sheet metal and machined assemblies to the aerospace, defence and nuclear power refuelling industries for over 70 years


he company has been involved in the development of major aero-engine programmes for both civil and military applications and has honed strong expertise when it comes to the production of value-added complex fabricated and machined components and assemblies. Previously under the name AGC AeroComposites - Derby, the company returned to its original name of Paul Fabrications in January 2017. Paul Fabrications’ VP and Managing Director, Kevin Brown discusses this development: “Our organisation recognized the history, value and pedigree behind the original Paul Fabrications name and made the strategic decision to operate under the legacy name. Our parent company, AGC AeroComposites, has also rebranded to Unitech Aerospace and all of its companies are branded under their original legacy names; these include Unitech Composites,


North Coast Composites, North Coast Tool and Mold, Tods Aerospace and Tods Defence.” Working in 60,000 square feet of manufacturing space in the East Midlands (UK), the company’s 145 employees reinforce the reputation that Paul Fabrications has built through the successful application of sound engineering principles that ensure the everchanging demands of customers are met. Moreover, personnel take pride in consistently exceeding the expectations of customers when it comes to both the delivery and quality of products. These strengths have resulted in an enviable customer base that includes world leading aerospace organisations and long-term contracts with both nuclear and aerospace clients. “Springfield Fuels is our main nuclear customer with a relationship lasting over 50 years and our products going into all


UK nuclear power stations. Our aerospace customers include Rolls-Royce, strategically located close to our Derby facility, MTU, Safran, ITP, Meggitt and FACC. We are particularly proud to have received a recent major contract award from Rolls-Royce based on our collaborative approach to conducting business,” says Kevin. Indeed, while Paul Fabrications has strong orders for 2017 that will result in more than 50 per cent revenue growth to the business; the main increase stems from the company’s long-term strategic partnership with Rolls-Royce that was signed in October 2016. “Historically, the business did not have a strategic relationship with Rolls-Royce, but today a collaborative approach centred around a deeper understanding of how we can add value has led us to a strong partnership with common goals. We will work together to manage a growing portfolio of both volume and legacy parts and we are now starting to see the benefits of being a larger and more strategic supplier to Rolls-Royce. This is a long-term relationship and we see this relationship growing significantly over the coming years. The key to our success is in execution and this is our absolute

| Paul Fabrications Ltd

focus,” says Wayne Exton, CEO of Unitech Aerospace. “This partnership is a critical part of the ongoing transformation of Rolls-Royce’s supply chain for metallic fabrications and was signed based upon our ability and commitment to provide a turnkey new product introduction (NPI) process. This innovative, integrated process will embed a Rolls-Royce team inside of Paul Fabrications’ Derby site allowing for new levels of collaboration, transparency and risk reduction between the two organisations. The ultimate goal is to significantly reduce RollsRoyce’s time to market and risk levels through a consolidation of its mature legacy products,” elaborates Kevin. Not only benefiting from longterm expertise in the aerospace and defence industries, the company boasts an impressive manufacturing plant that ensures complex projects are completed on time and to the best possible quality. Current key manufacturing and test capabilities include sixaxis fibre laser drilling and cutting machines, five-axis CO2 laser cutting machines, three, four and five-axis CNC milling machines; turning, hot and cold forming, resistance fusion and welding

equipment, heat treatment up to 1100 degrees Celsius, CMM and optical inspection and nondestructive testing, which includes x-ray inspection. “Paul Fabrications produces highly technical and complex products. The effective use of capital to ensure we have a world-class plant and equipment is essential to our competitive advantage. We will stay ahead of the curve by working in partnership with Rolls-Royce and our other customers using a common technology roadmap to carefully plan our future capital deployment on state-of-the-art machinery. When you walk into any Unitech Aerospace business, you are going to experience a premier facility, people who take pride in what they do and strong management practices,” says Wayne. With a state-of-the-art manufacturing facility, the financial strength of its parent company and long-term experience, the future looks positive for Paul Fabrications as it continues to deliver high quality solutions to its demanding customer base. “We will strive to continue the transformation of our business so we are positioned to meet our customers’ expectations of 100 per cent quality and on-time delivery whilst also providing a seamless new product introduction process. Our company’s vision is to ‘deliver solutions together,’ and we firmly believe that by embracing this approach and continuing to invest in both our business and employees, we will see year-onyear growth,” Kevin concludes. M

Paul Fabrications Ltd Products: Advanced manufacturing and engineering expertise for a wide variety of metallic precision products and assemblies found in commercial and military aircraft, nuclear reactors and power generation turbines 29

Strength in

numbers Operating as part of Unitech Aerospace, Tods Aerospace and Tods Defence specialise in the engineering, design and manufacture of advanced materials technology for aerospace and naval acoustic structures



| Tods Aerospace and Tods Defence 31


Tods Aerospace and Tods Defence


ods Aerospace was established in 1932 as W&J Tod Limited and transitioned into boat building and defence work during the 1960s before finally joining the Unitech family in 2013. The company is based in Crewkerne, Somerset and today represents an industry leader in the design and manufacture of complex composite structures for the aerospace, rail and defence markets. Within this dynamic group of companies, Tods Aerospace specialises in the engineering, design and manufacture of advanced materials for the aerospace sector, while Tods Defence is focused on serving clients within the naval and defence industries. During its

Tods Aerospace is extremely customer focused and we strive for superior quality, on-time delivery, customer value and satisfaction. This is complemented by world-class design and engineering history of operating within the aerospace sector, Tods Aerospace has provided products and advanced support services to prestigious industry operators including Rolls-Royce, Leonardo Helicopters, Airbus, BAE Systems, Zodiac Interiors and Hitachi Rail. By operating as a key part of Unitech Aerospace, Tods Aerospace is able to leverage the strengths of the wider business to gain further efficiency and

generate further benefits for its clients. “Through our membership of Unitech Aerospace we have gained additional financial strength with an added capability for investment to grow the company’s product portfolio. We can draw on the expertise and support within the group to achieve a greater offering for our customers, as well as access to a larger customer base,” reveals Vice President and Managing Director, Peter Eckersall. “Tods Aerospace has been a recognized and respected brand in the industry for over 30 years and merging this reputation with Unitech Aerospace results in a very powerful combination. Having the support of a talented and experienced senior executive team also further provides the

Desktop Engineering Desktop Engineering (DTE) has been a supplier to the TODS Group of companies for nearly 10 years, supplying advanced engineering software for design and analysis. As a partner with the major software author Dassault Systèmes, we have supplied and supported CATIA PLM software enabling TODS to design and manage information within its engineering design teams. Furthermore, TODS is a user of NASTRAN and PATRAN written by MSC Software and supplied and supported by DTE throughout this period. Its level of high use places technical demands on our support team and we are pleased TODS continues to use this service. 33


Tods Aerospace and Tods Defence

stability and direction to allow each individual business within the group to flourish and grow.”

World-class engineering Throughout all of its operations, Tods Aerospace is dedicated to providing its clients with the highest standards in quality, in accordance with the strictest industry certifications and customer requirements. This includes more than 30 separate qualification specifications for composite, sandwich and bonding related works. These qualifications are continually kept up to date, while new process credentials that are demanded by the manufacturing industry are further incorporated through on-going investment and training. “Tods Aerospace is extremely customer focused and we strive

Westec Precision Limited Having worked closely with Tods Aerospace and Defence divisions for a number of years, Westec Precision has developed a dynamic working relationship that improves production processes and manufacturing techniques through innovative tooling and special purpose equipment solutions. Having the opportunity to offer our expertise to assist the development of Tods marketleading products has been an interesting and rewarding experience that we hope will continue for many years.

for superior quality, on-time delivery, customer value and satisfaction. This is complemented by world-class design and engineering, which enables the business to provide a complete composite solution,” Peter says. “This incorporates concept design, process development, qualification support, manufacture, repair and full through-life maintenance. We are fully committed to investing in technology and people to support future state-of-the-art developments with continuous improvement through lean practices, staff development and training throughout the business.”

Modern facilities Tods Aerospace presently maintains three production sites, with two located at Crewkerne and the other in Portland, 35

Dorset. Each of these sites is AS9100 approved and the two Crewkerne sites are additionally NADCAP approved for composite manufacture. The company operates an extensive array of equipment including three clean rooms, four autoclaves, two fiveaxis CNC machines, an X-ray and NDI lab, reticulation machine and curing ovens. Tods Aerospace also operates two design offices that employ industry standard design tools comprised of CATIA, NASTRAN/PATRAN and MARC with configuration control using ENOVIA PLM. These enable vital design operations relating to: • Types of analysis • Stress analysis – Static, fatigue and dynamic • Requirements – Safety, environmental • Acoustic analysis – Sonar domes • RF analysis – For radome construction • Testing • Material qualification - Strength and environmental “The company’s facilities are constantly developed to meet


Tods Aerospace and Tods Defence

the challenges of a continually changing industry and dynamic customer requirements. New product introduction and adapting manufacturing technology alongside continuous lean activity, means that Tods Aerospace is always challenging itself to improve the layout and capability of its facilities. Being part of Unitech Aerospace has supported this development and during 2016 we invested in an X-ray capability, additional paint facility, larger autoclave, new digital curing ovens and our reticulation capability,” Peter details. “Investment in people and personal development is also a core value within the company. We have a very successful apprentice scheme and graduate

training scheme. All employees have a personal development plan and all staff will go through some type of formal or workplace-based training while working with Tods Aerospace.” While Tods Aerospace has already achieved a strong reputation with both new and existing clients, which is further bolstered by its membership of Unitech Aerospace, the company will seek to expand its reputation even further during the coming years. This it will do by placing a high priority to achieving the 100 per cent on-time delivery of products, while maintaining the highest levels of quality. “We will continue to utilise the financial strength of Unitech Aerospace alongside our own capability

for investment to grow the company’s product portfolio,” Peter concludes. “Perfect delivery and quality performance through continued lean initiatives and investment in new technologies will equally remain a high priority, as well as continued investment in people through apprenticeships, vocational training and graduate training schemes. All of these initiatives will further allow Tods Aerospace to develop a stronger supply chain that is inclusive to looking to identify low cost countries for further growth.” M

Tods Aerospace / Tods Defence Services: Complex aerospace solutions 37

Aerospace composites and tools North Coast Composites Tool and Mold manufactures advanced composites and tooling for the aerospace industry


orth Coast is made up of two business units: North Coast Tool & Mold Corporation, founded in 1976, and North Coast Composites, founded in 2003. Both business units are located in a 65,000 square foot facility in Cleveland, Ohio and are ISO9001 and AS9100 certified. In July 2016, North Coast was purchased and became part of Unitech Aerospace. Eddie Morrison, Vice President and General Manager of North Coast was keen to explain the reasons behind the partnership with Unitech Aerospace. “We were very much a stand alone business prior to being acquired by



| North Coast Composites Tool and Mold

Unitech Aerospace. We didn’t have a lot of capital investment and selling the business to Unitech provided the access to capital that we needed. Furthermore, Unitech brought improved business practices and a larger portfolio of customers. What was originally a small company without a lot of leverage has now formed meaningful relationships with the bigger customers that Unitech has access to.� North Coast specialises in the development of complex, high tolerance composites and is an industry expert in Resin Transfer Molding (RTM), 39

North Coast Composites Tool and Mold

vacuum-assisted resin transfer molding (VARTM), lay-up molds, compression molds, bond tools, invar tooling plastic injection molds, assembly jigs, trim & drill and machining fixtures, investment cast dies, handling equipment, stretch form dies, turnkey manufacture work cells and contract machining. It provides turnkey solutions for RTM/VARTM and resin impregnated parts, including product-design assistance, tool design and fabrication, prototype part fabrication, manufacturing planning assistance, and production part fabrication. The company’s main focus right now is on resin transfer molding: “Our core competency is in RTM and the majority of the parts we manufacture are resin transfer molding based. We make large containment cases for the Honeywell HTF7000 Series Engine, ducts for the new GE LEAP engine and inlet guide vanes for the B-1B Lancer Bomber. The applications


are varied, but its mainly all RTM now. We are starting to move towards compression molding and will be focusing more on these components this summer,” says Eddie. This is an exciting development for the company as it has been given the go ahead to manufacture compression molding components for the military helmet heads up displays, a see through display that sits directly in a pilot’s line of sight to significantly increase the perception of environmental elements. “We are going to provide compression molding components for the heads up display and have invested in a brand new press to carry out the work. We expect to complete the contract by the end of the year and will be looking for additional compression work,” explains Eddie. In 2016, North Coast produced over 1550 composite assemblies with a 100 per cent on-time delivery record. The tooling side of the company supports the manufacturing

side of the business. The sector develops tools for its own company and produces precision mold tools, holding fixtures, trim fixtures, assembly fixtures, breakdown autoclave tooling and steel and invar autoclave tooling for its customers. Currently it’s the tooling side of the business that has attracted most of the company’s international interest, and its biggest tooling job is for the French owned multinational aircraft company Safran. Membership and recognition by worldwide organisations highlights the level of service provided by the company. “As a National Aerospace and Defense Contractors Accreditation Program (NADCAP) certified manufacturer, we instill confidence in our clients that North Coast Composites is a vendor with unmatched quality, highly responsive, and industry-leading services for the dynamic global aerospace industry,” explains Eddie. “Our strategic vision for the next three years is to double the business. The tooling side of things currently represents about a third of the group. We are purchasing a lot of new equipment including new CNC machines. We want to expand the area of tooling so we can deliver larger fixtures and more complex tools. We’ve spoken to our customers about this and they are excited about moving forward with us. Regarding the composite side of the business, we have a reputation for being able to create complex parts that other companies can not do. We already work with the likes of Honeywell, GE, and IAI and we are striving towards expanding our portfolio in 2017,” concludes Eddie. M

North Coast Composites Tool and Mold Services: Manufactures composites for the aerospace industry, and tools to support its work and other companies


growth S Suncor, Inc. is a structural steel fabricator with offices in Hialeah, Florida and DeForest, Wisconsin - it provides structural steel products throughout the US 42

ince its foundation in 1992, Suncor Inc has built a solid reputation in the market for structural steel fabrication thanks to its strong performance and customer-centric approach to business. As such, the company has provided structural steel to a wide range of industries and buildings, working on notable projects such as industrial buildings, airport expansions, medical buildings, offices and schools to name a few. Looking back at the early days of Suncor Inc is Managing Director Doug Kuiper: “The initial focus on any start-up company is survival.

Creating cash flow and selling the first contract is always difficult. My personal background is within the engineering sector as well as drafting related to structural steel fabrication so I used these skills to generate income. Once this was accomplished, I started bidding on small jobs in Florida and other regions; the next challenge was to establish a location where we could successfully create a market for fabricated structural steel. After experimenting with three different regions we settled on southeast Florida where we found a stronger demand for our goods and services. From


there I partnered with other steel fabrication companies who preferred to work on a labor only basis outside the region to produce the products we sold; once a market for steel products had been created, I was able to back away from the technical side and manage the projects. About three years later, I was able to increase my staff and increase our volume.” It is in this Tri-County region of Southeast Florida where Suncor Inc. created a loyal and returning customer base. This is attributed to its focus on meeting customer requirements in an efficient and quality-centric manner, as Doug notes: “In those early days, once we had increased our staff and volume, rather than booking more contracts I focused on maintaining the same quantity of contracts but sought larger contract amounts. After we survived five years in operation, I felt confident we would be a successful company. I believe we have maintained this success because of our focus on solidifying customer relationships;

when it comes to priorities this is placed highest on the list because happy customers will be repeat customers. I believe that profitability will take care of itself with a strong and returning client base.” A year later, Suncor built offices in DeForest, Wisconsin and Hialeah, Florida. These premises were not purchased until Suncor Inc., which was developed around a zero-debt strategy, had the money to build them in 2007 and 2008 respectively.

Diverse markets To further enhance operations, the company established a sister company, National Metals, in June 2009. Handling the manufacturing of specialty metal

Indeed, not only can it handle huge construction projects, Suncor is also capable at delivering smaller, customized specialty projects that require unique and intricate details

| Suncor Inc

products, National Metals is certified by the American Institute of Steel Construction. “Since our inception and up until 2008 our primary market was providing structural steel for public schools, mostly K-8 and high schools; however, after the bank collapse, this all changed,” says Doug. The public school market began a depressed phase from which it still has not recovered. Suncor Inc has since diversified its markets to retain a well balanced customer base spread out over many sectors. “Even though the public school market has not returned, we have seen an increase in the amount of charter schools being built over recent years. There are a number of reasons for this increase in charter schools, for one thing, some parents want to be more involved and this offers the opportunity to be. Moreover, these schools also offer teachers the chance to be more innovative, so this has a strong appeal to certain faculties as well as students who have a strong interest in a certain 43

area; these students will also be attracted to these programs such as science, technology, engineering or math (STEM). We feel that building charter schools will represent around 20 per cent of our volume over the next several years and perhaps longer.” He continues: “Nevertheless, based on our learning experience from 2008, we realize nothing lasts forever. For the health of the firm, it is important for Suncor to remain in many different markets rather than focus on just one or two. We are currently offering structural steel products in the areas of aviation, healthcare, public and private schools, gaming, industry and hotels.” Although Suncor has developed its reputation on expertise within structural steel fabrication, providing the foundation for


retail facilities, office expansions and so on, the company has also mastered the finer art of this complex process. Indeed, not only can it handle huge construction projects, Suncor is also capable at delivering smaller, customized specialty projects that require unique and intricate details. Products created by the company include specialty canopies, custom rails, egg crate grilles, perforated metal rails, pan stairs with picket rails, sun shades and aluminum walkways.

Technology investment While diversification of market segments and services has financially strengthened and cemented Suncor Inc’s role as a structural steel fabricator to trust, the company is also keen to stay ahead of the competition

Suncor Inc

through investment in cutting edge machinery and equipment. “Five years ago we realized we had to change our detailing program from a 2D CAD program to a 3D modelling program. We use a Tekla modelling program that is integrated with new equipment that we have purchased over the last few years to speed up production without having to add manpower,” says Doug. With state-of-the-art efficiency and quality enhancing equipment and a broad customer base, Suncor Inc is keen to continue serving its loyal clients in the State of Florida as well as up the east coast of the United States while also sourcing opportunities for growth further afield. “Our focus over the next 12 months will not change much, except that we would like to focus on

larger structural steel projects in New England, where steel is the building material of choice as opposed to concrete that is prevalent in the southern states,” Doug concludes. M

Suncor Inc Services: Steel fabricator and provider of structural steel products 45

Harnessing horsepower Since 1918, Twin Disc power transmission technology has been changing the way the world works



or nearly 100 years, the company has remained a leader in designing and manufacturing the most innovative heavy-duty industrial equipment. Its products can be found in the drivelines and powertrains of a huge array of equipment—from tractors, trucks and turbines to work boats and pleasure craft. Its line-up includes powershift transmissions, mechanical and hydraulic power take-offs, gearboxes, torque converters, pump drives, air clutches, electronic shift controls and universal control drives. The company’s story began with a unique twin disc clutch designed to make a farm tractor more reliable, more productive and easier to operate. It worked like a charm and helped to revolutionize the agricultural equipment industry. One innovation led to another, and today Twin Disc has

built a worldwide reputation on its ability to engineer and build power transmission and propulsion systems for a vast array of applications. In fact, Twin Disc’s basic powershift automatic transmission design has proven so strong and versatile it has evolved into all sorts of niches. For example, manufacturers of aircraft rescue and firefighting (ARFF) vehicles all over the world routinely specify Twin Disc automation transmission systems. Military transport trucks and tank retrievers endure the rigors of the battlefield, utilising Twin Disc transmissions. And oil and gas field operations use Twin Disc transmissions to harness the huge horsepower of cementing and fracturing trucks. The company’s marine propulsion products – transmissions including the revolutionary QuickShift,


| Twin Disc

Innovation is one of the driving forces behind the success at Twin Disc and this is supported by its superlative manufacturing capabilities – summed up by the phrase ‘if we can think it, we can build it’

Arneson Surface Drives, Rolla Propellers, electronic controls, and the Express Joystick System – continue to set the industry standards for high performance applications. Furthermore, it is far and away the world’s leading supplier of power take-offs (PTOs) and clutches for heavyduty applications such as wood chippers, tub grinders, rock crushers, irrigation pumps and marine installations. Thanks to a rigorous dedication to continuous development and a highly-experienced research and development (R&D) department, over the last 12 months numerous solutions have been announced and launched, which demonstrate the level of engineering expertise and service afforded to its customers by Twin Disc. As recently as January 2017 the organisation announced the a new ‘Remote Over Center’ PTO, the RO

314/311. The innovative product uses a patent-pending design to remotely engage the over-center mechanism in the company’s proven SP 314/311 PTO and is complementary to the previously released RO114/RO214. The RO 314/311 can be engaged and disengaged remotely via a control valve and/or electronic control when machinery configurations or location hinder easy access to activation. Hydraulic or pneumatic actuation is achieved through ports, making access to the fittings uncomplicated and straightforward. Hydraulic or pneumatic pressure is required only to engage or disengage the PTO; the fluid or air supply can be shut off when not needed. Without the constant hydraulic or pneumatic flow of other designs, the unit’s clutch operation is far more efficient and cost-effective than that of

its competition. The RO 314/311 is dimensionally similar to the current mechanical SP 314/311. It continues to utilize three 14” friction plates in the 314 and three 11” plates in the 311. Existing SPs may be field converted to an RO using kits available from Twin Disc. The advanced design of the PTO allows for side load and inline applications. External cooling, filtration or a rotary union are not needed. Built strong to last, the RO 314/311 excels in a wide range of industrial applications including agriculture, construction, manufacturing, marine, mining, timber, and oil and gas production. The units are installed by OEMs and in custom settings.

HP800 launched The RO 314/311 was followed up by another debut in March (at CONEXPO-CON/AGG, in Las 47

Vegas, Nevada) of the HP800, a middle horsepower range option in its industrial lineup of heavy-duty, hydraulically-actuated PTOs. With an impressive maximum power rating of 800 hp at 1800 rpm, the HP800 is built to deliver serious muscle where other PTOs would falter. It’s ideal for driving pumps, grinders, crushers, dredgers, chippers, shredders, heavy-duty drills and other severe applications. Like Twin Disc’s first hydraulically actuated PTO, the HP1200, the HP800 has a modular design allowing for either side-load “P” or in-line “I” applications with the simple change of bearing carriers. An advanced control system allows for smooth engagement of the driven equipment. A key feature of the HP800 is the auxiliary drive pump towers with 400 hp maximum capacity


per tower, or 450 hp maximum for both. They’re rotatable by 0°, 45° and 90°, either clockwise or counter-clockwise, to allow for clearance in any installation. Optional speed increase ratios of 0.77:1 and 0.83:1 are available. Pads and splines are easily interchangeable to accommodate varying pump sizes. Sizes SAE A through SAE E are available.

Innovation A popular option that can be built into the HP800 is an integrated reservoir. Unlike a separate, externally mounted unit, it saves space and reduces installation cost. This innovative design allows for the installation of the standard charge/lube pump on a separate pad, freeing up all four auxiliary pads for customer use. A spring applied, hydraulically released

brake (SAHR) has been added as a standard feature. An integral, mechanical brake release allows the output shaft to easily be rotated if the driven equipment becomes jammed. An innovative, high-capacity brake with control logic is offered as an option. It slows the output when driving large masses in a shorter amount of time. The HP800 is available with SAE #0 (SAE J617) input housing and 18” SAE 460 (SAE J620) input coupling, or SAE #1 input housing and 14” SAE 355 input coupling. Initially offered with a dual auxiliary pump tower, a single tower version will be released at a later date. It is clear from just these two examples that innovation is one of the driving forces behind the success at Twin Disc and this is supported by its superlative

Twin Disc

manufacturing capabilities – summed up by the phrase ‘if we can think it, we can build it’. The company has invested in the finest computer controlled machine tools and organized them in the most efficient, effective and flexible manufacturing floor plans. It cross trains its operators so that they can quickly adapt to changing production line orders. Its flexible, cell-based manufacturing facilities can adapt quickly to create new products as they are developed. Its manufacturing centers in the US and Europe are certified under the provisions of ISO 9001.

Trusted brand It also has an approach where rather than supplying individual components, Twin Disc designs, engineers and manufactures carefully matched power

transmission systems. All the elements of the system – transmission, torque converters, fluid couplings, electronic controls – are designed to work together to transmit power from the source to the work – quickly, efficiently, smoothly and reliably. Twin Disc successfully builds products for so many diverse applications because it controls every step from development, from research and engineering to manufacturing to sales and service. It has the engineering and application experience to anticipate the power transmission or propulsion challenges a machine, vehicle, or marine craft will face, and has the resources to develop a specific product solution to meet those challenges. This philosophy not only produces innovative designs,

but also allows customers to integrate Twin Disc products into their production lines, which provides the end user with a better performing product while increasing the original equipment manufacturer’s brand value. With its unique engineering skills and manufacturing expertise, Twin Disc delivers systems that offer incomparable effectiveness and efficiency under the most gruelling conditions. With a vast network of distributor and dealer locations around the world, Twin Disc is more than just a name that customers know – it is one they can trust. M

Twin Disc Services: Manufacturer and distributor of power transmission equipment 49

Global supply As a full service provider of global manufacturing and supply chain management services, Marketing & Engineering Solutions (MES) has developed a strong customer base that includes some of the largest OEMs and OEM suppliers in the US, Europe and Australia



| Marketing & Engineering Solutions 51


lobal sourcing and supply chain management firm MES has achieved significant success since it was founded by Hiten Shah in 2007; establishing its Ohio warehouse the same year, the company went onto achieve ISO 9001 certification a mere two years later. Opening its India sourcing office in 2010, the company went global in 2011 with the establishment of its China office and a 3PL warehouse in Mexico; incorporating its Hong Kong business the same year, the company went on to establish a warehouse in California in 2012. Following this period of major expansion, MES began to source products from Vietnam and Taiwan in 2013 and achieved a stratospheric 220 per cent growth in sales in comparison to sales in 2012. Not a company to rest on its laurels, the company inaugurated its own warehouse in Mexico and Houston in 2014 while also becoming a beneficiary of the IMMEX programme in Mexico. Following this major growth and success, the company won a number of awards in 2015, while Hiten Shah became an Ey Entrepreneur of the Year 2015 finalist in Ohio Valley. Further awards were achieved in 2016, the same year the company completed its first acquisition and entered the hydraulics industry, reached 100 employees across the globe and launched a one-ofa-kind, cross-department, tool of data storage and analytics known as MESH. As of March 2017, the company was honoured to make the Inc. 500 ranking as one of the fastest growing companies in the US and to also achieve, for the fourth year in a row, the Columbus Business First’s Fast 50 Award. Complementing each other, the two awards recognise the incredible growth rate of MES, which has gone from $30 million revenue in 2013 to


As of March 2017, the company was honoured to make the Inc. 500 ranking as one of the fastest growing companies in the US $75 million forecast for 2016. Indeed, these two awards exemplify the relentless passion and talent of the individuals at MES who strive every day to ensure customers receive optimum quality products and services. “In the business of delivering engineering solutions, we work with various OEMs and tier one suppliers to develop a range of industrial components such as castings, machined parts, forgings, plastics and rubber parts. Working primarily in lighting, agriculture and electrical and telecom components, we are currently involved in a number of projects that include the development of a light housing casting, with a tooling lead time of just four to five weeks; providing parts in this short time frame has helped us gain a lot of business over recent years. To maintain this competitive edge, we have a very tight project

time frame and we work with suppliers that can deliver to our expectations,” says Hiten Shah, Founder and President of MES. He continues: “Another major project for us involved an engineering change from a machined component to a forged copper component for a significant cost savings to the customer. The challenge with this project was that the component required a 99.995 per cent purity. As such, we did a lot of engineering work and conducted a design of experiments (DOE) with various providers from India, Europe and Japan; trials were undertaken at a facility in India to ensure we could achieve the purity level that the customer wanted. “Currently approximately 60 per cent of our business is lighting; the agriculture segment meanwhile, is where we anticipate interesting developments and growth over the next 24 months. The automotive segment is less than 15 – 20 per cent of our business. We anticipate good growth in automotive market over the next five years.”

Worldwide operations Headquartered in Columbus, Ohio, the company today has offices

Marketing & Engineering Solutions

and warehouses dotted across the globe. Operating as a trading hub for global operations, the main activities for MES Hong Kong include direct purchasing from suppliers in mainland China, Taiwan, Malaysia, India, Vietnam and other countries in Asia as well as the management of negotiations, logistics and supply chain pricing. Acting as a consultant to suppliers, MES Hong Kong ensures quality improvement processes and provides its usual services while also acting as parent company of Ningbo Metrics, a supply chain, sourcing and trading firm that is based in the Zhejiang province of China. The main activities performed by Ningbo Metrics include supplier research and audits, supplier development, quality audits and inspection services, supplier quality management activities and purchasing and sourcing.

Focus on India Alongside Ningbo Metrics, the company has Bombay Metrics, a Mumbai based supply chain, sourcing and trading company that also provides services such as supplier research and audits, quality audits and inspection services, purchasing and sourcing. While Mumbai is the economic hub and commercial financial centre of India, it is also well connected to the rest of India, making it the perfect place for MES to benefit from the recent aggressive development in the production of metals, chemicals, automobiles and electronics. “Over the last year-and-a-half we have focused on India, which is partly due to India gaining a new prime minister, Mr Modi, who has put a number of initiatives in place; additionally, Indian manufacturers are becoming very competitive compared to China or Vietnam,” says Hiten. It is within these strategic locations that 100 associates deliver engineering solutions

to customers within industries that include lighting, industrial, automotive and agriculture. The range of talented staff within MES include six sigma engineers, sourcing experts, quality inspectors, supply chain experts, sales and account managers, business analysts and support staff. Striving to acquire talented and skilled employees in the international locations it operates in, the company retains employees by giving them a strong sense of autonomy, encouraging trust and integrity and providing a transparent and fair environment that feels more like a family; keen to develop personnel, MES also provides oneon-one coaching and training.

Delivering the best Firm in its belief that customers don’t have to settle when it comes to quality, speed and price when sourcing internationally, MES ensures optimum customer satisfaction across the globe thanks to its “win-win solutions” mission to its global customers. Inspiring organisations to turn away from compromise, the company ensures its supplier focus on delivering the best and thus, becoming the best. Looking ahead, Hiten sees opportunities for further growth and success for MES as the company seeks to increase its presence throughout Europe and Mexico while also continuing to improve its supply chain, quality metrics and inventory management metrics with the goal of enhancing its excellent reputation for customer service. “This is the secret recipe to our success and what we focus on every day, every month, every quarter and every year,” Hiten concludes. M

Marketing & Engineering Solutions Products: Delivering Engineered Solutions Supply chain and Global sourcing 53

Yazaki is the world’s largest manufacturer and marketer of automotive wiring harness systems and supplier of innovative solutions to all OEMs.

Here, our special focus has always been on creating a reasonable balance between our customers’ needs and a responsible use of our environment.

Our product portfolio contains smart junction boxes, control modules, connectors & terminals, highvoltage systems, instrument clusters, displays and components.

CONNECT to the Future - to reach this goal constant innovation is necessary.

The success story of the family-owned company began in Japan in 1929. We now have more than 289.000 committed and highly motivated employees working at 478 locations in 45 countries contributing to Yazaki’s global success. Customers appreciate our expertise and core competencies in consulting, development, industrialization and manufacturing.

Our guiding principal is vertical integration and the constant optimization of products, processes and services. Modern and customer specific solutions are only possible through the close interaction of electronics, electrical components and wire harnesses whether applying fast BUS systems like Ethernet for highly flexible platforms or product scaling in a challenging global market. Yazaki connects its customers with the future – worldwide.


| Ricardo

Drive for success Ricardo is renowned for delivering class-leading, cutting edge services and products to customers in sectors such as transportation, energy and scarce resource


he history of Ricardo stems back to the childhood of Harry Ricardo, who from a very young age was interested in all things propulsion and even built steam engines as a child. As Harry’s passion for propulsion continued, he went on to design and build his first combustion engine by the age of 17; this was used to pump water from the well at the family home. Forming Ricardo in 1915, Harry became one of the foremost engine experts of his generation and received a knighthood for his work in internal combustion engineering in 1948. The first major project for Ricardo took place in 1915, when Harry was commissioned to apply his advanced combustion knowledge to the mark five tank engine. To solve the issue of smoke emission, Harry came up with an engine that not only significantly lowered the copious amounts of smoke but was also far more powerful; more than 8000 of these engines saw military service since 1917, making it the first engine to be mass produced. Following this innovative development, the company went on to create the turbulent cylinder head during 1918 and 1919; this was a low cost

combustion system that increased the power of side valve gasoline engines. The variable compression ratio E35 research engine, developed in 1919, followed, and enabled the combustion properties of fuels to be accurately analysed; this innovation also laid the groundwork for today’s octane rating system. Over recent years, the company has strengthened its foothold in the motorsport arena, a development caused by the Ricardo’s invention of viscous coupling in the 1980s. Viewed as one of the company’s most significant transmission innovations, viscous coupling transformed world rallying in the pioneering group b rally cars. The runaway success of these four wheel drive cars led to a whole new market sector for all wheeled drive passenger cars and led to Ricardo assisting the likes of Bugatti and McLaren in delivering high quality, high specification engineered solutions. In 2001 the company assisted Bugatti in the 55

ASSO WERKE was established in 1973, carrying on the activity of Pistoni Asso, initially started by Mr. Silvano Ferrucci in 1949. Today his daughter Mrs. Elda Ferrucci who is continuing her father’s mission holds the company’s ownership. In early times ASSO WERKE had the opportunity to mature significant experiences in the piston manufacturing area: the two stroke combustion engines represented one of the main strengths of the whole production. Later on the product range has been extended to cover all main engine applications, both for mass production and competition: automotive - petrol and diesel -, motorcycles, scooters, karts, snowmobiles, off-road vehicles (ATV), marine, light agriculture machines, air and refrigerating compressors. Currently ASSO WERKE produces in-house pistons, cylinders and cylinder liners, piston rings and gudgeon pins, with a complete engineering service, going from the client preliminary data entry requirements to the part feasibility study, rapid prototyping and test bench samples, to the final high volume mass production. Special attention is given to the development of four stroke engine pistons for OEM high performance applications. For its parts ASSO WERKE can provide the customer with suitable advanced and superlative design solutions. ACT© special nickel and silicon carbide coating suitable for liners, with high wear resistance and oil retaining effects. PTWA© by Comau is our plasma spray coating suitable for automotive engine block coating solutions. KDN5© special ASSO WERKE patented piston ring alloy for superior tribological and durable behaviour. NIT: Gudgeon pins in nitrided aerospace steels, also with a selection of DLC coating specifications.

ASSO WERKE is able to produce cast and forged pistons for 2 and 4 stroke high performance applications using special aluminum alloys, with in-house produced low and high layer thickness selective anodizing treatments, suitable for long life turbocharged applications. In 2015 ASSO WERKE started with new challenges: become the reference point for forged piston manufacturers, starting from several innovative high fatigue property aluminium alloys to a state of art forging equipment.

Today many dream sportscars worldwide have an ASSO WERKE heart inside and we are proud to be the sole piston and cylinder liner supplier for the RICARDO’s engine programme.

T: +39 0587 282111 | F: + 39 0587 421760 | E: |


design, development and manufacture of driveline, a highly advanced, four wheel drive, dual clutch driveline system, for the world’s most powerful road car, the Bugatti Veyron. “This project is a clear example of our ability to engineer and manufacture complex and high value systems. A lot of traditional tier one companies can provide a full engineering service for their components or subsystems, but we offer something unique in our ability to take a clean sheet concept through to production and onto supply into the market. For the Bugatti Veyron project we provided all engineering, supply management and warranty management services for Bugatti throughout the lifecycle of the Veyron,” says Mark Garrett, Chief Operating Officer at Ricardo.

Cross industry skills Using this expertise, Ricardo went onto collaborate with McLaren on the design, development and manufacture of the M838T 3.8 litre twin turbo V8 engine; as part of the project, Ricardo also developed a dedicated assembly facility to supply the engines within a timeframe of 18 months. This groundbreaking engine has three times been named

At the heart of Ricardo’s success in a number of demanding business sectors is its forward thinking approach to market trends international Engine of the Year in the three to four litre category. While continuing to supply transmissions to many motorsport formulae and deliver world-firsts in four-wheel drive systems, the company also works in a range of sectors. One notable example of this is Ricardo’s work with JCB to deliver a groundbreaking solution for the JCB DieselMax in 2006. With the JCBDieselMax powered by two JCB444 backhoe loader diesel engines, the two companies worked together to boost the power to produce a total of 1500 horse-power from the two engines; in 2006, this vehicle took the FIA international diesel powered land speed record of 350.092 miles per hour. Having previously demonstrated its whole vehicle design capability with the US FED Alpha protected vehicle which delivered over 70 per cent fuel savings vs the current HHMMWV, Ricardo went onto deliver innovative solutions

in the defence sector with the development of the Ocelot/ Foxhound for the UK Ministry of Defence. The Ocelot/Foxhound was created from a clean sheet of paper through to full production in less than two years. “Another example of our ability to engineer and manufacture complex and high value systems is our successful project with the British Army on the Foxhound/Ocelot light protected patrol vehicle. Developed to support troops in Afghanistan, we were involved in the project from the start, working with Force Protection Industries, now part of GDLS, to bring this vehicle to market. In total we manufactured 376 vehicles, which are in service with the British Army today,” highlights Mark. At the heart of Ricardo’s success in a number of demanding business sectors is its forward thinking approach to market trends, its commitment to innovation and its cross industry skills, the latter of which has resulted in the development of novel technologies that are then carried over into other business sectors. “One example of our cross industry skills is our strategic decision to bring sensor technology from the wind industry into the rail industry, which has 57


resulted in the monitoring and performance of the rail network and the ability to sense cracks appearing in rails before they become an issue,” reveals Mark. Another major strength of the company is its continued investment in facilities. In fact, the company marked the start of 2016 with the launch of a newly expanded engine assembly plant. While another state-of-the-art facility based in the Midlands has the equipment and machinery necessary to produce complete transmissions and driveline systems or produce separate components on a ‘make to print’ basis for a range of sectors. Ricardo is keen to stay ahead of the competition and has made further investments throughout the year. These include machine tools to ensure the machine shop can offer full prismatic facilities of turning and milling as well as wire erosion, shaping, hobbing, spiral bevel-axles, computerised heat treatment, grinding and gear grinding.

Collaboration commitment The prismatic machining offers 16 CNC and conventional lathes as well as 12 milling stations/ machining centres, which includes five axis and both horizontal and vertical capability; the horizontal machines with pallet change means that HPTP (High Performance Transmissions Products) Division are able to carry out transmission case

machining. Furthermore, the new Hofler PROMAT 400 machine offers non helical form or spur gear grinding. “We take a very pragmatic view in how we will continue to invest in our in-house manufacturing, but one of the most important aspects is our ability to support our programme development that in turn results in product development for our customers. The ability to machine one-off prototype components for engines, transmissions and hybrid systems gives us the flexibility and speed in then bringing products to market,” says Mark. “We also have high performance transmission production and manufacturing capability, which is an intense machining and heat treatment capability that enables us to develop high quality, high spec components for customers. In this area we do a lot of gear sets for motor sports as well as actuation components for the aerospace industry; we are also able to machine large castings, gear cases and transfer cases so we can manufacture and supply full transmission systems for our customer base in batch volumes.” Complementing these strengths is the company’s commitment to collaboration, whether that is with customers or organisations such as the University of Sheffield. “We are currently involved in the Advanced Manufacturing Research Centre collaboration, otherwise known

as AMRC, which is affiliated to Sheffield University that was funded originally by Boeing. We have signed a memorandum of understanding (MOU) to develop highly advanced manufacturing technologies that will allow the automotive industry to both make complex high value components in a cost effective manner. We have teamed up with AMRC to bring its background knowledge in high quality aerospace systems into the automotive space, which is then complemented by our expertise in the automotive sector. By applying this knowledge and experience that this joint partnership will bring some real added value to customers,” comments Mark. “AMRC has a lot of experience in complex machine tool processes, tool vibration and cutting speeds that enable them to look for fundamental improvements to machining processes and thus reduce operation times; the organisation also works with carbon fibre reinforced composites, complex assemblies and robotised assembly systems, which is where our knowledge of the automotive application and process advancements can bring something unique into the automotive sector,” he adds. With the project beginning in October 2016, Ricardo will remain focused on collaborating with some of the UK’s leading academic research groups, while also seeking out its own fuel efficient solutions to bring forward cutting edge technologies for the future generation. As demand increases for a more green planet, the company is committed to playing an integral role in the delivery of a lower carbon and increasingly sustainable transportation sector. M

Ricardo Products: Manufacture engines, transmissions, vehicle systems, intelligent transportation systems (ITS) and hybrid & electric systems 59



| Elekta


cancer care Elekta is an innovation leader in pioneering radiation therapy solutions, with imageguided radiotherapy at the forefront of what it does


lekta was founded in 1972 by Laurent Leksell and his father, Lars Leksell, a Swedish physician and Professor of Neurosurgery at the Karolinska Institute in Stockholm, Sweden. He was a pioneer in modern neurosurgery techniques and renowned as the inventor of radiosurgery and developer of the advanced radiosurgical platform, Leksell Gamma Knife®. This noninvasive method for treating brain disorders works by applying a single dose of high radiation to a small and critically located antracranial area through the skull. It is the preferred radiosurgical method for its precision, efficiency and exceptional therapeutic response. Today, Gamma Knife surgery is performed in hundreds of leading

hospitals and clinics around the world, to around 70,000 patients. No other non-invasive procedure in this field has greater clinical recognition. “Our history is what drives us forward. We have dedicated ourselves to pioneering advancements for cancer care,” said Global Vice President of Supply Chain and Manufacturing at Elekta, Steve Wort. “There have been many developments over the years since our beginnings. We are the leading innovator of equipment and software used to improve, prolong and save the lives of people with cancer and brain disorders. Elekta solutions are used in more than 6000 hospitals worldwide and we employ around 3600 people around the world,” explains Steve.

Professor Lars Leksell 61

Indeed, over the last four decades Elekta has grown and acquired Philips Radiation Therapy Division, which became Elekta Ltd in 1997. Additional key acquisitions include Neuromag in 2003, IMPAC Medical Systems Medical Intelligence in 2005, Beijing Medical Equipment Institute (BMEI) in 2006, 3D Line Medical Systems in 2007, CMS in 2008, Resonant Medical in 2010, Nucletron in 2011, Radon in 2012, and a number of key distributors, in line with market developments and its own strategic vision to gain a strong international presence in cancer care. Further innovative developments have taken place over the years advancing the company to the very forefront of radiation therapy. Elekta was the first to integrate CBCT and introduce


image-guided radiotherapy in 2003, developed the first Monte Carlo based treatment planning system in 2008, the first to introduce an analytics platform to mine MOSAIQ® data in 2014 and it developed the first on-line adaptive radiosurgery system, Leksell Gamma Knife® Icon™ in 2015. In addition to these significant advancements, Elekta has been working on a new and revolutionary machine for the oncology department.

Next generation An exciting breakthrough in the treatment of cancer is a new product called the MR-linac that has taken ten years to develop. “This is next-generation innovation for the treatment of cancer patients using radiotherapy. Development started in 2007 and


it’s the first high-field MR-linear accelerator of its kind,” said Steve. MR-linac integrates an ultramodern radiotherapy system and a highfield MRI scanner with advanced software that allows a physician to capture diagnostic quality images of tumours and surrounding tissue during treatment. The MR-linac is expected to improve tumour tissue targeting while reducing exposure of normal tissue and critical anatomical structures to the radiation. It will allow physicians to precisely locate a tumour and visually track it. This allows physicians to rapidly respond and offer personalised care. Elekta, its technology partner Philips, and the MRlinac consortium members are working to make the MR-linac a reality. MR-linac has the potential to fundamentally transform radiotherapy by enabling radiation

MR-linac has the potential to radically improve the precision of radiation delivery, through crystal clear imaging

oncologists to see the treatment target in real time, and to rapidly adapt the plan in response to diagnostic quality MR images. The technology fully integrates three subsystems to achieve unparalleled precision and accuracy in radiotherapy, an advanced linear accelerator that is manufactured by Elekta in Crawley, a 1.5 Tesla magnetic resonance imaging (MRI) system supplied by Philips and online adaptive workflow software. These three systems combined

allow for simultaneous radiation therapy delivery and high-field MR tumour monitoring, enabling online treatment alterations in response to changes in the targeted tumour position. It is hoped that the precision of the treatment will reduce patient concerns around after care. “Radiation plays a central role in approximately 50 per cent of patients who are ultimately cured of cancer, but still causes anxiety in patients who fear negative post-treatment side effects,” said Professor Kevin Harrington, Joint Head of the Division of Radiotherapy and Imaging at The Institute of Cancer Research, London and The Royal Marsden. “MR-linac has the potential to radically improve the precision of radiation delivery, through crystal clear imaging. We expect MR-linac to increase physician confidence in 63

Versa HD is designed to provide the precision and speed necessary to deliver advanced treatment techniques that demand maximum accuracy in tumor targeting



treating the intended target, while also putting patients at ease.” Currently the MR-linac is being tested in seven hospitals in the US and in Europe, including two sites in the UK. Consortium members are currently engaged in various stages of evaluation and are collaborating to establish new protocols for clinical research and develop methods for data collection and analysis. The system is undergoing thorough tests and various objects have been selected for shape and weight. Elekta is not only an innovation company, but it also values manufacturing excellence. The manufacturing side of the business happens within Europe, Asia and the US. The primary manufacturing site for the company’s linear accelerator in the UK is located in Crawley, West

Sussex. The company makes a significant contribution to the regional economy with around 200 manufacturing jobs in the UK supply chain. “Over the past years, we have had significant job growth at the Crawley facility, and we also work to develop young talent by hiring apprentices, many of whom are now in technical roles within the company,” concludes Steve. M

*Elekta’s MR-linac is a work in progress and has not yet been released or received regulatory approval for clinical use.

Elekta Services: Specialise in providing radiation therapy, radiosurgery, medical equipment and clinical management for the treatment of cancer and brain disorders 65

Dynamic and progressive As a leading name in global materials engineering, Wall Colmonoy has remained a pioneer in manufacturing for over 75 years


ating back to when Albert F. Wall founded the business during 1938 in Detroit, Michigan, Wall Colmonoy has persevered in the spirit of Mr. Wall’s entrepreneurial ambition, with a culture of innovative vision ever-present at the core of what shapes the ongoing success of the company. Today, Wall Colmonoy has grown into a global organisation that employs close to 400 staff, with offices in the US and UK. The company has had a presence within the UK since 1952. Wall Colmonoy Limited (UK), was originally based in Motherwell, Scotland, before moving to its current location in 1969 to the Welsh town of Pontardawe. The region was made attractive to Wall Colmonoy due to its rich


200-year metallurgical history and a readily available, highly skilled workforce. The town of Pontardawe also boasts a good source of qualified graduates from local Welsh universities and in close proximity to a major metal supplier at the Vale refinery, Clydach (formerly INCO Ltd). Wall Colmonoy Limited (WCL) is a US family-owned global leader in advanced materials engineering and has been a major employer in South Wales for close to 50 years. Managing Director, Steph Curtis explains: “WCL is a worldwide leader in manufacturing nickel and cobalt-based powdered alloys; castings and precision machined components. We provide advanced metal coatings, brazing, heat treatment and welding to aerospace standards. We currently


| Wall Colmonoy Ltd

Wall Colmonoy’s Precision Components for the Power Generation Industry

Wall Colmonoy’s Precision Components for the Glass Container Industry

employ around 170 members of staff within the UK and generate a turnover of £25 million annually, with 90 per cent of the company’s products being exported across Europe, Russia, Scandinavia, the Middle East and North Africa (MENA), South Africa and India. The products and services that the company provide play an integral role in many industries that are instrumental to our everyday lives. “We help our customers operate more efficiently and effectively. We develop value added solutions to minimise customers’ operational expenditure and extend product life. What does this mean? Well, it means, through the application of a wide range of powdered alloys, solving wear, corrosion, erosion and abrasion issues for parts like neck rings and plungers that

are used in glass bottle making; for continuous cast rolls in steel making; for downhole drilling tools in oil & gas extraction; for boilers in waste to energy plants; it means joining parts for high-temperature and corrosion applications like Exhaust Gas Recirculation units (EGR’s) and Catalytic Converters for automotive industry, for heat exchangers that are found in aerospace or power industries.” Wall Colmonoy is a diverse business – but it is focused on listening to its customers in order to meet their needs. “In a passionate, focused and disciplined manner, we are constantly developing products and applications in partnership with our customers - applying the skills and experience of our talented engineers and 67

metallurgists,” Steph declares. Wall Colmonoy brands include Colmonoy® (nickel) and Wallex® (cobalt) for hardsurfacing applications to extend useful life of components and Nicrobraz® (nickel), Niferobraz® (iron) and CuBrazTM (copper) brazing alloys and brazing aids for joining parts for hightemperature and corrosion applications for aerospace, automotive, energy, nuclear and defence. “Wall Colmonoy was established when Albert F. Wall met the metallurgists who had originally developed Colmonoy and subsequently purchased the patent and manufacturing processes. The word Colmonoy is the amalgam of the word alloy, and the names of the product’s original metallurgists, Cole and Edmonds, who invented the


specially formulated superior performing nickel-based alloy. Colmonoy is the original nickelbased hardsurfacing alloy and was originally developed for application on downhole drill bits for the oil industry. It now has many different applications in a variety of industries from glass container to steel,” Steph explains. “Wall Colmonoy is also a pioneer and leading expert in high temperature nickel-based brazing. In 1950 the company’s then Materials Engineer, Bob Peaslee, invented a new brazing technology involving nickel-based filler metals and hydrogen atmosphere furnaces. This product was named Nicrobraz. Mr. Peaslee pioneered the application of hydrogen braze for aircraft turbine engine components. The technology and process continues today.”

In order to advance and educate customers’ engineers on furnace brazing technology, Wall Colmonoy hosts a Brazing School that takes place at Wall Colmonoy EU Headquarters in Pontardawe and at Brazing Engineering Center in Cincinnati, USA. The first European school was held in October 2014 and Wall Colmonoy Limited (UK) has continued to host the school annually. The school teaches top engineers from around the world about high-temperature brazing. Since 1977 Wall Colmonoy Corporation (USA) has been hosting the brazing school in the USA. “We have world class employees, with a strong senior management team from a broad range of manufacturing industries; we have highly qualified professionals across the whole business - PHD’s,

Wall Colmonoy Ltd

Master’s Degrees, Bachelor’s Degrees, Diplomas, HNDs and HNCs. To collaborate and partner with our customers around the world, many of us speak many languages. We have extensive foreign language capability in French, German, Spanish, Russian, Turkish, Bulgarian, Punjabi and Urdu.”

Organisational change Recently, Wall Colmonoy Limited has been going through an important cultural and organisational change. “I joined in 2014 and before that worked for 30 years in several different industry sectors for major international PLC’s and SME’s. My background and experience is in strategic business improvement. We have recruited a new management team these last two years, and we have a very clear direction of where we are going. We are focused on continuous improvement and profitable growth – health, safety and welfare of our employees; quality, cost and delivery of first class products; technical support and customer service. We have applied lean management and manufacturing to our operations and in the last few years, we have made big steps forward in our thinking and quality. This is supported by continuous investment into the company’s technical and quality capabilities and manufacturing facilities,” Steph says. Wall Colmonoy is heavily investing in its UK facility and its people. Some key facility investments include introducing ESI ProCAST virtual prototyping software to optimise manufacturing process for precision cast components; adding and upgrading advanced testing equipment for powders in order to meet increased technical demands; and new machines for the machine shop to produce larger parts faster and more efficiently.

Home grown talent In order to develop the next generation of engineers and ensure its growth, Wall Colmonoy Limited launched a Bespoke Apprenticeship Programme focused on developing ‘Home Grown Talent’. It is a structured programme to meet the unique needs of the business and to ensure the development of specialist skills and technical knowledge needed for its growth. WCL hires apprentices who take part in a specific learning and development programme that involves rotating through the different divisions of the company for three-month periods, along with college study. The apprentices go one day a week to college to study engineering and learn the job first hand through a

structured work programme. “This is what we call ‘Home Grown Talent.’ In fact, our apprentices learn not only about the company, its products and processes, and quality, but it also means that we can ‘develop’ their minds, to align them with company culture and our corporate vision of where we want to be,” Steph explains. “Our apprenticeship programme is just a part of our training and development programme, there are several other initiatives as well. We have two young engineers doing an MBA (Master’s in Business Administration) and an Engineering Master’s programme, we also have one engineer who is going to do a PhD research project next year on the specifics 69

The word Colmonoy is the amalgam of the word alloy, and the names of the product’s original metallurgists, Cole and Edmonds, who invented the specially formulated superior performing nickel-based alloy


Wall Colmonoy Ltd

of what we do. We are doing a lot of this collaborating with the Welsh government.” Wall Colmonoy’s extensive experience in developing innovative products and continual investments in its people and facility has made WCL a market leader within advanced materials engineering. Indeed the company embodies a culture of rich manufacturing history and longevity that dates back over 75 years, including 48 years of proven industry excellence at its facility in Wales. This trusted market presence and an ongoing process of investment will prove vital in enabling WCL to navigate the market through a volatile period in the wake of the Brexit decision and changing industry demands. “Wall Colmonoy anticipates

major changes to take place in the coming years as economic, technological and sociological demands increase. In respect of this change we are at the frontier and will continue not only to embrace change, but also to positively influence it through our commitment to leadership, our people, innovation and our continuous improvement philosophy. We are developing a strong lean culture that is

focused on eliminating waste, being lean and agile. We are relentless in our pursuit of excellence and desire to become a world class enterprise,” he concludes. “We will continue to develop engineered solutions for our customers, helping them to improve their businesses and to seize new opportunities.” WCL has a dynamic culture based upon absolute customer focus and customer satisfaction, teamwork, employee engagement and development, relentless continuous improvement and aspiration for excellence in everything it does. M

Wall Colmonoy Ltd. Services: A leading global materials engineering company. 71


| Tele-Fonika Kable

Keeping connected Ranked in the forefront of the global cable industry, Tele-Fonika Kable SA (TF Kable) is the third largest manufacturer of cables and wires in Europe and sells its products to over 80 countries 73


stablished in April 1992 in the city of Myslenice, in close proximity to Krakow, Tele-Fonika civil partnership company began by constructing a modern and stateof-the-art production plant that specialised in the manufacture of copper, computer and fibre optic telecommunication cables. The company swiftly became a leading supplier in the Polish market and took the strategic decision to maintain its position in the market by initiating the production of advanced copper telecommunication cables that allow for data transfer in a bandwidth up to 100Mhz at a maximum speed of one Gbit/s. With market demand for its products booming by 1996, the company began doubling manufacturing capacity for that product group. One year on, the company progressed into the production of fiber optic cables and, following the purchase of advanced equipment by Nokia Maillefer, TF Kable was able to produce up to 216 strand fiber optic cables. To further strengthen


its foothold in the market, TeleFonika SC acquired a majority stake in Krakowska Fabryka Kabli SA (KFK), which specialises in rubber isolated cables. These developments resulted in the commissioning of a modern, automated and robotic production facility in Krakow - Bieżanów; this facility focuses on flexible highly stranded conductors, aluminium wire rods, aluminium alloy overhead aerial cables; trolley traction wires and PVC and building wires. With the acquisition of a majority stake in Elektrim Kable SA finalised in December 2001, a new entity was formed - Tele-Fonika Kable SA (TF Kable). As a result of two plants Bydgoska Fabryka Kabli and Fabryka Kabli Załom became part of the Tele-Fonika Kable Group and Ożarowska Fabryka Kabli was closed. Following further business developments, TF Kable today is the largest wire and cable manufacturer in Poland, operating from six production facilities and boasting a significant local market share. Benefiting from its impressive manufacturing

capabilities, the Group produces approximately 25,000 different products for its broad customer base, as Bartlomiej Zgryzek, Vice President at Tele-fonika Kable highlights: “The products offered by the Group are classified into six main categories: 1 kV cables, medium voltage and high voltage cables, telecom cables, wires, rubber isolated cables and other cables. Sales on the Polish market account for approximately 40 per cent of total revenues, with sales in foreign markets generating the 60 per cent; the core markets are Germany, the UK, the US and Baltic region countries.” He continues: “The main customers of TF Kable include wholesale network distribution companies, energy companies such as power plants, utilities and network operators; companies in the oil & gas and mining sector, the telecommunication segment, which includes telecom operators and their suppliers and large industrial companies.” Operating from six production facilities, four of which are based in Poland, the Group made the

Tele-Fonika Kable

strategic decision to go through a reorganisation process in 2013 that has led to each production plant in the country specialising in specific types of cables; this decision has enabled TF Kable to not only improve cost controls when it comes to production, but also logistics and sales processes. “TF Kable’s main competitive advantage lies in our high quality products and operational effectiveness,” says Bartlomiej. “Therefore, we have to compete by carefully controlling our operating costs above all as it seems to be the key to commercial success. The operational excellence is strongly supported by the complete specialisation of our production plants.”

Positive changes In more detail, the Group’s Myslenice plant today specialises in the production of telecommunication cables, while Krakow - Bieżanów specialises in processing copper and aluminium rods as well as manufacturing semi-finished products such as copper wires and cords. The Krakow Wielicka plant, meanwhile, is the largest cable producer for the power industry in Poland and produces a wide range of cables; these include power cables, control and signalling cables and special purpose cables such as rubber isolated cables. Bydgoszcz specialises in the production of power cables as well as selfsupporting and suspended cables, fittings and power cables. The two facilities that are abroad, Zajecal, in Serbia, and Czernichow, Ukraine, both specialise in low voltage cables, however, the Zajecal plant also produces building wires and rubber isolated cables, while Czernichow also manufactures building wires. The massive diversity of products and the superior production capability of plants has resulted in the Group’s involvement in a number of

major projects. For example, in 2011 the Group supplied power to one of the main Euro 2012 arenas, the National Stadium in Warsaw. For this project, the Group’s Bydgoszcz plant manufactured speciality high voltage cables, rated 110kV, with fiber optic cables; the cable line was approximately 510 metres and was installed in a conduit running under the Vistula River, cable conduit installation took place through the utilisation of Horizontal Directional Drilling (HDD). Proud of its commitment to shared principles and objectives when it comes to the ethical, sustainable and high quality cable development and manufacture, the Group became a member of Europacable, signed the Europacable Industry Charter in September 2015 and the CEO of Tele-Fonika Kable became the Vice-President of the Europacable Association. Having joined the ranks of Europacable, the Group not only gets opportunities to network with representatives of other cable market players, but also gains additional knowledge when it comes to respecting product quality and safety. Consistently focused on operational excellence and the delivery of high quality products, TF Kable anticipates further growth in the future following positive changes in the market since 2014. In response to these opportunities, the Group will further develop and expand its vast product portfolio with more complex products such as MV and HV cables and cables in line with European CPR requirements, which will thus enable it to meet the increasingly challenging needs of its customers across the globe. M

Tele-Fonika Kable Products: Copper and aluminium cables and wires and optical fibre cables 75

Care and

control Vernacare is a leading UK-based infection control business, whose innovative single-use system and award-winning products have made it a global leader in human waste management across the healthcare sector

V Matthew Miller, CEO


ernacare offers hygienic patient toileting and washing solutions through its range of innovative products that have revolutionised an area of healthcare that had not changed in many years. In 2015, the company produced around 160 million disposable products, all of which were made in accordance with tight Quality Assurance systems, confirming how reliable and robust its products are. The company works to the highest national and international standards possible, everything it makes being BSI Kitemarked. Vernacare’s products

offer customers and patients an effective solution that is cost effective, environmentally friendly and designed to prevent infection. This is why the Vernacare system is overwhelmingly used in healthcare across the UK, while also widely used worldwide. From its inception over 50 years ago to the present day, the business has held a belief in innovation, which it supports with an extensive in-house research and development team and large-scale investments in the company’s capabilities. There are a number of improvements that the business has made to


its facilities in recent years. One example of this is a multi-million pound investment in automated packing and inspection processes, another is its automated data collection and process monitoring using smart sensors, and there are many more. The innovation and facilities enable Vernacare to provide products that offer minimal environmental impact, enhanced care facility productivity, gold standard infection prevention as well as maximum patient and carer dignity, all at a reduced cost. The Vernacare System has disrupted the traditional method of re-using bedpans, urinals and wash bowls. Vernacare produces single-use containers made from renewable natural fibres, which are then disposed of in its Vortex machines which break down the used containers and contents into miniscule particles using a fast and energy efficient cold water process. The resulting fine slurry flows freely through the drains. Over the years Vernacare’s offer has evolved and diversified into a range of products based upon the same hygienic, cost effective and environmentally friendly solution. Chief Executive Matthew Miller discussed the environmental benefits Vernacare offers: “We are an eco-friendly ISO 14001 accredited business, which has invested in a range of environmental management improvements to our manufacturing process, such as energy reduction and water recycling.” Matthew continued: “For our customers the Vernacare system uses 60 per cent less water than some alternative systems and less energy because our Vortex disposal machines use a cold water process and operate a fast, energy efficient cycle.” He added: “In recent years, Vernacare’s products have also won many plaudits as they avoid the environmental cost of chemically and thermally

disinfecting plastic or metal containers and their ultimate disposal.”

Award winners In addition to these benefits, Vernacare’s disposable products assist nurses in making best use of their time and abilities, which can be better applied in other aspects of patient care. On this Matthew explained: “The Vernacare single-use system saves nurses more than 27 hours per year – compared to alternative reusable systems. It also improves working conditions by eliminating the time spent washing plastic products.” The Vernacare system offers great value, as Matthew confirmed: “When all costs are considered our system is 39 per cent cheaper to maintain than alternative systems of human

| Vernacare

waste management. Our singleuse process utilises significantly less energy and water than alternative re-usable methods. Further financial benefits are provided through the savings in nursing time, the cost of treating Healthcare Acquired Infections (HCAIs) and reduced maintenance costs. Also, the Vortex disposal unit can often be significantly less costly to purchase than many washer disinfectors.” The Vernacare single-use system is a valuable tool in combating some of the most infectious and pervasive illnesses, that if allowed can rapidly spread throughout a hospital. Matthew commented: “By providing patients with a new disposable product every time, the Vernacare system helps to reduce 77

infection risk from Clostridium difficile (C.diff), MRSA, E. Coli and Norovirus, and other highly infectious diseases, such as the Middle East respiratory syndrome coronavirus (MERS-CoV).” Vernacare offers these benefits across a large range of products, which includes the world’s first detergent-proof disposable washbowl, for which it won the prestigious Queen’s Award for Innovation, once again displaying its originality and expertise. These talents were also important in creating its Vortex+ model, launched in 2015, a waste disposal unit that does not require any operator hand contact, thus helping to reduce cross-infection. Also, it has recently developed a new model of its successful VernaChair commode, which combats infection through an easy-clean design. In


addition, Vernacare has once again displayed its leadership within the industry with the introduction of a single-use female urinal, the VernaFem, an award winning innovation. Through all of these new groundbreaking developments, Vernacare focuses on developing cost effective products that place patient safety, comfort and dignity, as well as the environment, at the heart of all it does. Due to the important ways Vernacare benefits customers and patients, it is no wonder that it has revolutionised the healthcare sector, and is used by 96 per cent of NHS Trusts and healthcare facilities in 48 countries. The business also looks for growth in international markets and has been successful in identifying customers and markets around the world that have a demand for

its human waste management and infection control products.

New ideas The company has taken a fresh approach to how it targets international markets and as of 2013 it has now put in place a more targeted policy that aims to achieve high levels of growth. One


recent example of this is a new-five year deal which will see Vernacare supply Manipal – one of Asia’s largest healthcare management groups. The company expects to see over ten million pounds worth of sales to India over the next three years as a result, and with more interested parties in the region, the future for Vernacare

in India looks very positive. In addition to this, the business will also seek to develop its wellestablished market positions in all corners of the globe. The worldwide popularity of its products demonstrates how effective Vernacare has been in addressing old issues within healthcare with new ideas. It has underpinned all of this with a commitment to quality, to minimising its impact on the environment, whilst also improving the experience and cost for healthcare providers. Due to these factors the Vernacare System is considered to be the gold standard globally, and this reputation only looks set to grow as more customers worldwide convert to Vernacare’s products and experience their benefits. The almost complete

conversion of the UK to the single-use system, based on quality, cost effectiveness and the overall benefit to customers and patients has been a solid platform from which Vernacare has taken its innovative product range to many countries around the world and why it now looks set to increase its global share of the international healthcare market. Indeed, as prevention becomes increasingly important to health management, importance of cost benefits increase, and concerns for environmental issues grow Vernacare will no doubt enjoy even greater success. M

Vernacare Products: Hygienic patient toileting and washing and infection control 79








Manufacturing North America




Editor: Studio: Sales:

Manufacturing North America Issue 100  
Manufacturing North America Issue 100